Absorbent article with an exudate management layer

ABSTRACT

An absorbent article can have a topsheet layer, a liquid impermeable layer, and an absorbent core positioned between the topsheet layer and the liquid impermeable layer. The absorbent article can further include an exudate management layer in fluid communication with the topsheet layer. In various embodiments, the exudate management layer can be positioned on a body facing surface of the topsheet layer. In various embodiments, the exudate management layer can be positioned between the topsheet layer and the absorbent core. The exudate management layer has a first component which defines an opening for direct passage of body exudates into the absorbent core. The exudate management layer has a second component which at least partially overlaps the first component of the exudate management layer and further extends in the longitudinal direction of the absorbent article in a direction towards the posterior region of the absorbent article.

BACKGROUND OF THE DISCLOSURE

A primary function of a personal care absorbent article is to absorb andretain body exudates such as urine and fecal material with additionaldesired attributes including low leakage of the exudates from theabsorbent article and a dry feel to the wearer of the absorbent article.Currently, a wide variety of products for absorbing body exudates areavailable in the form of diapers, training pants, and incontinencedevices. These products generally have an absorbent core positionedbetween a body-facing liquid permeable topsheet layer and agarment-facing liquid impermeable layer. The edges of the topsheet layerand the liquid impermeable layer are often bonded together at theirperiphery to form a seal to contain the absorbent core and body exudatesreceived into the product through the topsheet layer. In use, suchproducts may have a front waist and a rear waist region which canencircle the lower torso of the wearer to remain in place on the body ofthe wearer.

Absorbent articles commonly fail, however, to prevent leakage of bodyexudates. Some body exudates, such as solid and semi-solid fecalmaterial, having difficulty penetrating the topsheet layer of theabsorbent article as easily as urine and tend to spread across thesurface of the topsheet layer under the influence of gravity, motion,and pressure by the wearer of the absorbent article. The migration ofsuch body exudates is often towards the perimeter of the absorbentarticle, increasing the likelihood of leakage and smears against theskin of the wearer which can make clean-up of the skin difficult.

An additional problem is that such conventional absorbent articleproducts may not always have an adequate fit to the body of the wearerwhich can lead to increased levels of leakage of body exudates from theproduct and discomfort during wear of the product. Many conventionalabsorbent article products are flat or have flat regions prior to usewhile the wearer's body is contoured. Even though the flat absorbentarticle product can bend during use, it can still fail to fully conformto the body of the wearer which can result in gaps between the productand the skin of the wearer resulting in leakage of body exudates,particularly those body exudates, such as solid and semi-solid fecalmaterial, which have a more difficult time penetrating the topsheetlayer of the product. The movement of the wearer can also causeundesirable deformation of the product and fold lines within the productwhich can create pathways along which the body exudates can travel andleak from the product.

There remains a need for an absorbent article that can adequately reducethe incidence of leakage of body exudates from the absorbent article.There remains a need for an absorbent article which can provide improvedhandling of body exudates. There remains a need for an absorbent articlethat can minimize the amount of body exudates in contact with thewearer's skin.

SUMMARY OF THE DISCLOSURE

In various embodiments, an absorbent article can have a longitudinaldirection and a transverse direction; a longitudinal centerline and atransverse centerline; an anterior region, a posterior region, and acentral region positioned between the anterior region and the posteriorregion; an anterior region transverse direction end edge, a posteriorregion transverse direction end edge, and a pair of longitudinaldirection side edges extending between and connecting the anteriorregion transverse direction end edge and the posterior region transversedirection end edge; a topsheet layer defining a body facing surface ofthe absorbent article, a liquid impermeable layer defining a garmentfacing surface of the absorbent article, and an absorbent corepositioned between the topsheet layer and the liquid impermeable layer;and an exudate management layer in fluid communication with the topsheetlayer; the exudate management layer comprising a first opening and asecond opening, wherein at least one of the first opening or the secondopening is further connected to a barrier component via a barriercomponent fold, the barrier component extending from the barriercomponent fold in the longitudinal direction towards the posteriorregion of the absorbent article.

In various embodiments, the exudate management layer comprises a firstcomponent at least partially defining the first opening and the secondopening.

In various embodiments, the exudate management layer comprises a firstcomponent at least partially defining the first opening and a secondcomponent at least partially defining the second opening wherein thesecond component is connected to the first component via a primary fold.In various embodiments, the exudate management layer is positioned onthe body facing surface of the topsheet layer. In various embodiments,the exudate management layer is positioned between the topsheet layerand the absorbent core.

In various embodiments, the absorbent article further has an acquisitionlayer.

In various embodiments, the barrier component comprises a secondaryfold.

In various embodiments, the second component at least partially overlapsthe first component.

In various embodiments, the second component at least partiallyunderlaps the first component.

In various embodiments, the article further comprises an opposing pairof containment flaps extending in the longitudinal direction of theabsorbent article.

In various embodiments, the topsheet layer is a fluid entangled laminateweb comprising a support layer comprising a plurality of fibers andopposed first and second surfaces; a projection layer comprising aplurality of fibers and opposed inner and outer surfaces, the secondsurface of the support layer in contact with the inner surface of theprojection layer, fibers of at least one of the support layer and theprojection layer being fluid-entangled fibers of the other of thesupport layer and the projection layer; a plurality of hollowprojections formed form a first plurality of the plurality of fibers inthe projection layer, the plurality of hollow projections extending fromthe outer surface of the projection layer in a direction away from thesupport layer; and a land area, wherein the plurality of hollowprojections are surrounded by the land area.

In various embodiments, the absorbent core comprises a body facingsurface and projections extending away from the body facing surface ofthe absorbent core.

In various embodiments, the barrier component comprises at least oneopening.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a side view of an exemplary embodiment of an absorbentarticle.

FIG. 2 is a top down view of an exemplary embodiment of an absorbentarticle with portions cut away for clarity.

FIG. 3 is a top down view of an exemplary embodiment of an absorbentarticle.

FIG. 4 is an exploded cross-sectional view of the absorbent article ofFIG. 3 taken along line 4-4.

FIG. 5 is a top down view of an exemplary embodiment of an absorbentarticle.

FIG. 6 is an exploded cross-sectional view of the absorbent article ofFIG. 5 taken along line 6-6.

FIGS. 7A-7F are perspective views of exemplary embodiments of exudatemanagement layers.

FIG. 8 is a top down view of an exemplary embodiment of an absorbentarticle.

FIG. 9 is an exploded cross-sectional view of the absorbent article ofFIG. 8 taken along line 9-9.

FIG. 10 is a top down view of an exemplary embodiment of an absorbentarticle.

FIG. 11 is an exploded cross-sectional view of the absorbent article ofFIG. 10 taken long line 11-1.

FIGS. 12A-12C are top down views of exemplary embodiments of exudatemanagement layers.

FIG. 13 is a perspective view of an embodiment of an exudate managementlayer.

FIG. 14 is a perspective view of an embodiment of an exudate managementlayer.

FIG. 15 is a perspective view of an exemplary embodiment of a topsheetlayer.

FIG. 16 is a cross-sectional view of the topsheet layer of FIG. 15 takenalong line 16-16.

FIG. 17 is a cross-sectional view of the topsheet layer of FIG. 15 takenalong line 16-16 showing possible directions of fiber movements withinthe topsheet layer due to a fluid entanglement process.

FIG. 18 is a photomicrograph of a cross-sectional view of a portion of afoam and fiber composite.

FIG. 19 is a photomicrograph of a planar view of the foam and fibercomposite of FIG. 16 such that the fibrous material is visible to theviewer.

FIG. 20 is a photomicrograph of a planar view of the foam and fibercomposite of FIG. 16 such that the second planar surface of the foammaterial and portions of fibers are visible to the viewer.

FIG. 21 is a perspective view of an exemplary embodiment of an absorbentarticle.

FIG. 22 is a perspective view of an exemplary illustration of a set-upof an imaging system used for determining the percent open area within afluid entangled laminate web.

FIG. 23 is a perspective view of an exemplary illustration of a set-upof an imaging system for determining projection height within a fluidentangled laminate web.

Repeat use of reference characters in the present specification anddrawings is intended to represent the same or analogous features orelements of the disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure is directed towards an absorbent article whichcan have an improved conformity to the body of the wearer of theabsorbent article providing for an improved intake and retention of bodyexudates such as urine and/or fecal material. An absorbent article canhave a longitudinal direction, a transverse direction, and a depthdirection. The absorbent article can have an anterior region, aposterior region, and a central region between the anterior region andthe posterior region. The absorbent article can have a topsheet layer, aliquid impermeable layer, and an absorbent core positioned between thetopsheet layer and the liquid impermeable layer. The absorbent articlecan further include an exudate management layer in fluid communicationwith the topsheet layer. In various embodiments, the exudate managementlayer can be positioned on a body facing surface of the topsheet layer.In various embodiments, the exudate management layer can be positionedbetween the topsheet layer and the absorbent core. The exudatemanagement layer has a first opening for direct passage of bodyexudates, such as urine, into the absorbent core and a second openingfor direction passage of body exudates, such as fecal material, into theabsorbent core. In various embodiments, at least one of the firstopening or second opening of the exudate management layer is associatedwith a barrier component via a barrier component fold.

Definitions

As used herein, the term “absorbent article” refers herein to an articlewhich may be placed against or in proximity to the body (i.e.,contiguous with the body) of the wearer to absorb and contain variousliquid, solid, and semi-solid exudates discharged from the body. Suchabsorbent articles, as described herein, are intended to be discardedafter a limited period of use instead of being laundered or otherwiserestored for reuse. It is to be understood that the present disclosureis applicable to various disposable absorbent articles, including, butnot limited to, diapers, training pants, youth pants, swim pants, andincontinence products, and the like without departing from the scope ofthe present disclosure.

As used herein, the term “airlaid” refers herein to a web manufacturedby an airlaying process In the airlaying process, bundles of smallfibers having typical lengths ranging from about 3 to about 52 mm areseparated and entrained in an air supply and then deposited onto aforming screen, usually with the assistance of a vacuum supply. Therandomly deposited fibers are then bonded to one another using, forexample, hot air to activate a binder component or a latex adhesive.Airlaying is taught in, for example, U.S. Pat. No. 4,640,810 to Laursen,et al., which is incorporated herein in its entirety by referencethereto for all purposes.

As used herein, the term “bonded” refers to the joining, adhering,connecting, attaching, or the like, of two elements. Two elements willbe considered bonded together when they are joined, adhered, connected,attached, or the like, directly to one another or indirectly to oneanother, such as when bonded to an intermediate element. The bonding canoccur via, for example, adhesive, pressure bonding, thermal bonding,ultrasonic bonding, stitching, suturing, and/or welding.

As used herein, the term “bonded carded web” refers herein to webs thatare made from staple fibers which are sent through a combing or cardingunit which separates or breaks apart and aligns the staple fibers in themachine direction to form a generally machine direction oriented fibrousnonwoven web. This material may be bonded together by methods that caninclude point bonding, through air bonding, ultrasonic bonding, adhesivebonding, etc.

As used herein, the term “coform” refers herein to composite materialscomprising a mixture or stabilized matrix of thermoplastic fibers and asecond non-thermoplastic material. As an example, coform materials maybe made by a process in which at least one meltblown die head isarranged near a chute through which other materials are added to the webwhile it is forming. Such other materials may include, but are notlimited to, fibrous organic materials such as woody or non-woody pulpsuch as cotton, rayon, recycled paper, pulp fluff, and alsosuperabsorbent particles, inorganic and/or organic absorbent materials,treated polymeric staple fibers and so forth. Some examples of suchcoform materials are disclosed in U.S. Pat. No. 4,100,324 to Anderson,et al., U.S. Pat. No. 4,818,464 to Lau, U.S. Pat. No. 5,284,703 toEverhart, et al., and U.S. Pat. No. 5,350,624 to Georger, et al., eachof which are incorporated herein in their entirety by reference theretofor all purposes.

As used herein, the term “conjugate fibers” refers herein to fiberswhich have been formed from at least two polymer sources extruded fromseparate extruders and spun together to form on fiber. Conjugate fibersare also sometimes referred to as bicomponent or multicomponent fibers.The polymers are arranged in substantially constantly positioneddistinct zones across the cross-sections of the conjugate fibers andextend continuously along the length of the conjugate fibers. Theconfiguration of such a conjugate fiber may be, for example, asheath/core arrangement where one polymer is surrounded by another, ormay be a side-by-side arrangement, a pie arrangement, or an“islands-in-the-sea” arrangement. Conjugate fibers are taught by U.S.Pat. No. 5,108,820 to Kaneko, et al., U.S. Pat. No. 4,795,668 toKrueger, et al., U.S. Pat. No. 5,540,992 to Marcher, et al., U.S. Pat.No. 5,336,552 to Strack, et al., U.S. Pat. No. 5,425,987 to Shawver, andU.S. Pat. No. 5,382,400 to Pike, et al., each being incorporated hereinin their entirety by reference thereto for all purposes. For twocomponent fibers, the polymers may be present in ratios of 75/25, 50/50,25/75 or any other desired ratio. Additionally, polymer additives suchas processing aids may be included in each zone.

As used herein, the term “machine direction” (MD) refers to the lengthof a fabric in the direction in which it is produced, as opposed to a“cross-machine direction” (CD) which refers to the width of a fabric ina direction generally perpendicular to the machine direction.

As used herein, the term “meltblown web” refers herein to a nonwoven webthat is formed by a process in which a molten thermoplastic material isextruded through a plurality of fine, usually circular, die capillariesas molten fibers into converging high velocity gas (e.g., air) streamsthat attenuate the fibers of molten thermoplastic material to reducetheir diameter, which may be to microfiber diameter. Thereafter, themeltblown fibers are carried by the high velocity gas stream and aredeposited on a collecting surface to form a web of randomly disbursedmeltblown fibers. Such a process is disclosed, for example, in U.S. Pat.No. 3,849,241 to Buten, et al., which is incorporated herein in itsentirety by reference thereto for all purposes. Generally speaking,meltblown fibers may be microfibers that are substantially continuous ordiscontinuous, generally smaller than 10 microns in diameter, andgenerally tacky when deposited onto a collecting surface.

As used herein, the term “nonwoven fabric” or “nonwoven web” refersherein to a web having a structure of individual fibers or threads whichare interlaid, but not in an identifiable manner as in a knitted fabric.Nonwoven fabrics or webs have been formed from many processes such as,for example, meltblowing processes, spunbonding processes, through-airbonded carded web (also known as BCW and TABCW) processes, etc. Thebasis weight of nonwoven webs may generally vary, such as, from about 5,10, or 20 gsm to about 120, 125, or 150 gsm.

As used herein, the term “spunbond web” refers herein to a webcontaining small diameter substantially continuous fibers. The fibersare formed by extruding a molten thermoplastic material from a pluralityof fine, usually circular, capillaries of a spinneret with the diameterof the extruded fibers then being rapidly reduced as by, for example,eductive drawing and/or other well-known spunbonding mechanisms. Theproduction of spunbond webs is described and illustrated, for example,in U.S. Pat. No. 4,340,563 to Appel, et al., U.S. Pat. No. 3,692,618 toDorschner, et al., U.S. Pat. No. 3,802,817 to Matsuki, et al., U.S. Pat.No. 3,338,992 to Kinney, U.S. Pat. No. 3,341,394 to Kinney, U.S. Pat.No. 3,502,763 to Hartman, U.S. Pat. No. 3,502,538 to Levy, U.S. Pat. No.3,542,615 to Dobo, et al., and U.S. Pat. No. 5,382,400 to Pike, et al.,which are each incorporated herein in their entirety by referencethereto for all purposes. Spunbond fibers are generally not tacky whenthey are deposited onto a collecting surface. Spunbond fibers maysometimes have diameters less than about 40 microns, and often betweenabout 5 to about 20 microns.

As used herein, the terms “superabsorbent polymer,” “superabsorbent,” or“SAP” shall be used interchangeably and shall refer to polymers that canabsorb and retain extremely large amounts of a liquid relative to theirown mass. Water absorbing polymers, which are classified as hydrogels,which can be cross-linked, absorb aqueous solutions through hydrogenbonding and other polar forces with water molecules. A SAP's ability toabsorb water is based in par on iconicity (a factor of the ionicconcentration of the aqueous solution), and the SAP functional polargroups that have an affinity for water. SAP are typically made from thepolymerization of acrylic acid blended with sodium hydroxide I thepresence of an initiator to form a poly-acrylic acid sodium salt(sometimes referred to as sodium polyacrylate). Other materials are alsoused to make a superabsorbent polymer, such as polyacrylamide copolymer,ethylene maleic anhydride copolymer, cross-linkedcarboxymethylcellulose, polyvinyl alcohol copolymers, cross-linkedpolyethylene oxide, and starch grafted copolymer of polyacrylonitrile.SAP may be present in absorbent articles in particle or fibrous form oras a coating or another material or fiber.

Absorbent Article:

The present disclosure is directed towards an absorbent article whichcan have an improved conformity to the body of the wearer of theabsorbent article providing for an improved intake and retention of bodyexudates such as urine and/or fecal material. An absorbent article canhave a longitudinal direction, a transverse direction, and a depthdirection. The absorbent article can have an anterior region, aposterior region, and a central region between the anterior region andthe posterior region. The absorbent article can have a topsheet layer, aliquid impermeable layer, and an absorbent core positioned between thetopsheet layer and the liquid impermeable layer. The absorbent articlecan further include an exudate management layer in fluid communicationwith the topsheet layer. In various embodiments, the exudate managementlayer can be positioned on a body facing surface of the topsheet layer.In various embodiments, the exudate management layer can be positionedbetween the topsheet layer and the absorbent core. The exudatemanagement layer has a first opening for direct passage of bodyexudates, such as urine, into the absorbent core and a second openingfor direction passage of body exudates, such as fecal material, into theabsorbent core. In various embodiments, at least one of the firstopening or second opening of the exudate management layer is associatedwith a barrier component via a barrier component fold.

Referring to FIGS. 1-6 and 8-11 , an absorbent article 10 of the presentdisclosure is exemplified in the form of a diaper. It is to beunderstood that the present disclosure is suitable for use with variousother absorbent articles which are designed to be worn about the lowertorso of a wearer, such as, but not limited to, training pants or adultincontinence pants, without departing from the scope of the presentdisclosure. FIG. 1 is a side view of an exemplary embodiment of theabsorbent article 10 and FIG. 2 is a top down view of an exemplaryembodiment of an absorbent article 10 with portions cut away forclarity. FIGS. 3-6, and 8-10 provide further illustrations of exemplaryembodiments of an absorbent article 10 with an exudate management layer40.

The absorbent article 10 can have a longitudinal direction (X), atransverse direction (Y), and a depth direction (Z). The absorbentarticle 10 can have an anterior region 12, a posterior region 14, and acentral region 16 located between the anterior region 12 and theposterior region 14. The absorbent article 10 can have a firsttransverse direction end edge 20, a second transverse direction end edge22 opposed to the first transverse direction end edge 20, and a pair ofopposing longitudinal direction side edges 24 extending between andconnecting the first and second transverse direction end edges, 20 and22. The absorbent article 10 can have a wearer facing, liquid permeabletopsheet layer 30 and a garment facing, liquid impermeable layer 36. Anabsorbent core 38 can be positioned between the topsheet layer 30 andthe liquid impermeable layer 36. The absorbent article 10 can have anexudate management layer 40 in fluid communication with the topsheetlayer 30. In various embodiments, the exudate management layer 40 can bepositioned on a body facing surface 32 of the topsheet layer 30 such as,for example, illustrated in the exemplary embodiments illustrated inFIGS. 3, 4, 8, and 9 . In various embodiments, the exudate managementlayer 40 can be positioned between the topsheet layer 30 and theabsorbent core 38 such as, for example, illustrated in the exemplaryembodiments illustrated in FIGS. 5, 6, 10, and 11 . The topsheet layer30 and the liquid impermeable layer 36 can both extend beyond theoutermost peripheral edges of the absorbent core 38 and can beperipherally bonded together, either entirely or partially, using knownbonding techniques to form a sealed peripheral region. For example, thetopsheet layer 30 and the liquid impermeable layer 36 can be bondedtogether by adhesive bonding, ultrasonic bonding, or any other suitablebonding technique known in the art.

In various embodiments in which the absorbent article 10 is a diaper,training pant, youth pant, swim pant, or an incontinence product such asan adult incontinence pant, the absorbent article 10 can be worn aboutthe lower torso of the wearer and can have a waist opening 230 and legopenings 232. The absorbent article 10 can have leg elastic members, 240and 242, which can be bonded to the liquid impermeable layer 36 such asby, for example, an adhesive, generally adjacent the lateral outer edgesof the liquid impermeable layer 36. Alternatively, the leg elasticmembers, 240 and 242, may be disposed between other layers of theabsorbent article 10. A wide variety of elastic materials may be usedfor the leg elastic members, 240 and 242. Suitable elastic materials caninclude sheets, strands or ribbons of natural rubber, synthetic rubber,or thermoplastic elastomeric materials. The elastic materials can bestretched and secured to a substrate, secured to a gathered substrate,or secured to a substrate and then elasticized or shrunk, for example,with the application of heat, such that the elastic retractive forcesare imparted to the substrate.

In various embodiments, the absorbent article 10 can have waist elasticmembers, 244 and 246, which can be formed of any suitable elasticmaterial. In such an embodiment, suitable elastic materials can include,but are not limited to, sheets, strands or ribbons of natural rubber,synthetic rubber, or thermoplastic elastomeric polymers. The elasticmaterials can be stretched and bonded to a substrate, bonded to agathered substrate, or bonded to a substrate and then elasticized orshrunk, for example, with the application of heat, such that elasticretractive forces are imparted to the substrate. It is to be understood,however, that the waist elastic members, 244 and 246, may be omittedfrom the absorbent article 10 without departing from the scope of thisdisclosure.

In various embodiments, the absorbent article 10 can include a fastenersystem. The fastener system can include one or more back fasteners 250and one or more front fasteners 252. Portions of the fastener system maybe included in the anterior region 12, posterior region 14, or both. Thefastener system can be configured to secure the absorbent article 10about the waist of the wearer and maintain the absorbent article 10 inplace during use. In an embodiment, the back fasteners 250 can includeone or more materials bonded together to form a composite ear as isknown in the art. For example, the composite fastener may be composed ofa stretch component 254, a nonwoven carrier or hook base 256, and afastening component 258.

Topsheet Layer:

The topsheet layer 30 defines a body facing surface 32 of the absorbentarticle 10 that may directly contact the body of the wearer and isliquid permeable to receive body exudates. The topsheet layer 30 isdesirably provided for comfort and functions to direct body exudatesaway from the body of the wearer, through its own structure, and towardsthe absorbent core 38. The topsheet layer 30 desirably retains little tono liquid in its structure, so that it provides a relatively comfortableand non-irritating surface next to the skin of the wearer of theabsorbent article 10.

The topsheet layer 30 can be a single layer of material, oralternatively, can be multiple layers that have been laminated together.The topsheet layer 30 can be constructed of any material such as one ormore woven sheets, one or more fibrous nonwoven sheets, one or more filmsheets, such as blown or extruded films, which may themselves be ofsingle or multiple layers, one or more foam sheets, such as reticulated,open cell or closed cell foams, a coated nonwoven sheet, or acombination of any of these materials. Such combination can beadhesively, thermally, or ultrasonically laminated into a unified planarsheet structure to form a topsheet layer 30.

In various embodiments the topsheet layer 30 can be constructed fromvarious nonwoven webs such as meltblown webs, spunbond webs,hydroentangled spunlace webs, or through air bonded carded webs.Examples of suitable topsheet layer 30 materials can include, but arenot limited to, natural fiber webs (such as cotton), rayon,hydroentangled webs, bonded carded webs of polyester, polypropylene,polyethylene, nylon, or other heat-bondable fibers (such as bicomponentfibers), polyolefins, copolymers of polypropylene and polyethylene,linear low-density polyethylene, and aliphatic esters such as polylacticacid. Finely perforated films and net materials can also be used, as canlaminates of/or combinations of these materials. An example of asuitable topsheet layer 30 can be a bonded carded web made ofpolypropylene and polyethylene such as that obtainable from SandlerCorp., Germany. U.S. Pat. No. 4,801,494 to Datta, et al., and U.S. Pat.No. 4,908,026 to Sukiennik, et al., and WO 2009/062998 to Texol teachvarious other topsheet materials that may be used as the topsheet layer30, each of which is hereby incorporated by reference thereto in itsentirety. Additional topsheet layer 30 materials can include, but arenot limited to, those described in U.S. Pat. No. 4,397,644 to Matthews,et al., U.S. Pat. No. 4,629,643 to Curro, et al., U.S. Pat. No.5,188,625 to Van Iten, et al., U.S. Pat. No. 5,382,400 to Pike, et al.,U.S. Pat. No. 5,533,991 to Kirby, et al., U.S. Pat. No. 6,410,823 toDaley, et al., and U.S. Publication No. 2012/0289917 to Abuto, et al.,each of which is hereby incorporated by reference thereto in itsentirety.

In various embodiments, the topsheet layer 30 may contain a plurality ofapertures formed therethrough to permit body exudates to pass morereadily into the absorbent core 38. The apertures may be randomly oruniformly arranged throughout the topsheet layer 30. The size, shape,diameter, and number of apertures may be varied to suit an absorbentarticle's 10 particular needs.

In various embodiments, the topsheet layer 30 can have a basis weightranging from about 5, 10, 15, 20, or 25 gsm to about 50, 100, 120, 125,or 150 gsm. For example, in an embodiment, a topsheet layer 30 can beconstructed from a through air bonded carded web having a basis weightranging from about 15 gsm to about 100 gsm. In another example, atopsheet layer 30 can be constructed from a through air bonded cardedweb having a basis weight from about 20 gsm to about 50 gsm, such as athrough air bonded carded web that is readily available from nonwovenmaterial manufacturers, such as Xiamen Yanjan Industry, Beijing, DaYuanNonwoven Fabrics, and others.

In various embodiments, the topsheet layer 30 can be at least partiallyhydrophilic. In various embodiments, a portion of the topsheet layer 30can be hydrophilic and a portion of the topsheet layer 30 can behydrophobic. In various embodiments, the portions of the topsheet layer30 which can be hydrophobic can be either an inherently hydrophobicmaterial or can be a material treated with a hydrophobic coating.

In various embodiments, the topsheet layer 30 can be a multicomponenttopsheet layer 30 such as by having two or more different nonwoven orfilm materials, with the different materials placed in separatelocations in the transverse direction (Y) of the absorbent article 10.For example, the topsheet layer 30 can be a two layer or multicomponentmaterial having a central portion positioned along and straddling alongitudinal centerline 18 of an absorbent article 10, with lateral sideportions flanking and bonded to each side edge of the central portion.The central portion can be constructed from a first material and theside portions can be constructed from a material which can be the sameas or different from the material of the central portion. In suchembodiments, the central portion may be at least partially hydrophilicand the side portions may be inherently hydrophobic or may be treatedwith a hydrophobic coating. Examples of constructions of multi-componenttopsheet layers 30 are generally described in U.S. Pat. No. 5,961,505 toCoe, U.S. Pat. No. 5,415,640 to Kirby, and U.S. Pat. No. 6,117,523 toSugahara, each of which is incorporated herein by reference thereto inits entirety.

In various embodiments, a central portion of a topsheet layer 30 can bepositioned symmetrically about the absorbent article 10 longitudinalcenterline 18. Such central longitudinally directed central portion canbe a through air bonded carded web (“TABCW”) having a basis weightbetween about 15 and about 100 gsm. Previously described nonwoven,woven, and aperture film topsheet layer materials may also be used asthe central portion of a topsheet layer 30. In various embodiments, thecentral portion can be constructed from a TABCW material having a basisweight from about 20 gsm to about 50 gsm such as is available fromXiamen Yanjan Industry, Beijing, DaYuan Nonwoven Fabrics, and others.Alternatively, aperture films, such as those available from such filmsuppliers as Texol, Italy and Tredegar, U.S.A. may be utilized.Different nonwoven, woven, or film sheet materials may be utilized asthe side portions of the topsheet layer 30. The selection of suchtopsheet layer 30 materials can vary based upon the overall desiredattributes of the topsheet layer 30. For example, it may be desired tohave a hydrophilic material in the central portion andhydrophobic-barrier type materials in the side portions to preventleakage and increase a sense of dryness in the area of the sideportions. Such side portions can be adhesively, thermally,ultrasonically, or otherwise bonded to the central portion along oradjacent the longitudinally directed side edges of the central portion.Traditional absorbent article construction adhesive may be used to bondthe side portions to the central portion. Either of the central portionand/or the side portions may be treated with surfactants and/orskin-health benefit agents, as are well known in the art.

Such longitudinally directed side portions can be of a single ormulti-layered construction. In various embodiments, the side portionscan be adhesively or otherwise bonded laminates. In various embodiments,the side portions can be constructed of an upper fibrous nonwoven layer,such as a spunbond material, laminated to a bottom layer of ahydrophobic barrier film material. Such a spunbond layer may be formedfrom a polyolefin, such as a polypropylene and can include a wettingagent if desired. In various embodiments, a spunbond layer can have abasis weight from about 10 or 12 gsm to about 30 or 70 gsm and can betreated with hydrophilic wetting agents. In various embodiments, a filmlayer may have apertures to allow fluid to permeate to lower layers, andmay be either of a single layer or multi-layer construction. In variousembodiments, such film can be a polyolefin, such as polyethylene havinga basis weight from about 10 to about 40 gsm. Construction adhesive canbe utilized to laminate the spunbond layer to the film layer at anadd-on level of between about 0.1 gsm and 15 gsm. When a film barrierlayer is used in the overall topsheet layer 30 design, it may includeopacifying agents, such as film pigments, that can help the film inmasking stains along the absorbent article 10 side edges, therebyserving as a masking element. In such a fashion, the film layer canserve to limit visualization of a fluid insult stain along the absorbentarticle 10 side edges when viewed from above the topsheet layer 30. Thefilm layer may also serve as a barrier layer to prevent rewet of thetopsheet layer 30 as well as to prevent the flow of fluid off the sideedges of the absorbent article 10. In various embodiments, the sideportions can be laminates such as aspunbond-meltblown-meltblown-spunbond layer (“SMMS”) laminate,spunbond-film laminate, or alternatively, other nonwoven laminatecombinations.

In various embodiments, the topsheet layer 30 can be a fluid entangledlaminate web 160 with projections 162 extending outwardly and away fromat least one intended body-facing surface of the laminate web 160 suchas illustrated in FIGS. 13-15 . In various embodiments, the projections162 can be hollow. The laminate web 160 can have two layers such as asupport layer 164 and a projection layer 166. The support layer 164 canhave a first surface 168 and an opposed second surface 170 as well as athickness 172. The projection layer 166 can have an inner surface 174and an opposed outer surface 176 as well as a thickness 178. Aninterface 180 can be present between the support layer 164 and theprojection layer 166. In various embodiments, fibers of the projectionlayer 166 can cross the interface 180 and be entangled with and engagethe support layer 164 so as to form the laminate web 160. In variousembodiments in which the support layer 164 is a fibrous nonwoven web,the fibers of the support layer 164 may cross the interface 180 and beentangled with the fibers of the projection layer 166.

In various embodiments, the projections 162 can be filled with fibersfrom the projection layer 166 and/or the support layer 164. In variousembodiments, the projections 162 can be hollow. The projections 162 canhave closed ends 182 which can be devoid of apertures. In variousembodiments, however, it may be desirable to create one or moreapertures in each of the projections 162. Such apertures can be formedin the closed ends 182 and/or side walls 184 of the projections 162.Such apertures are to be distinguished from interstitial fiber-to-fiberspacing which is the spacing from one individual fiber to the nextindividual fiber.

In various embodiments, the projections 162 can have a percentage ofopen area in which light can pass through the projections 162 unhinderedby the material forming the projections 162, such as, for example,fibrous material. The percentage of open area present in the projections162 encompasses all area of the projection 162 wherein light can passthrough the projection 162 unhindered. Thus, for example, the percentageof open area of a projection 162 can encompass all open area of theprojection 162 via apertures, interstitial fiber-to-fiber spacing, andany other spacing within the projection 162 where light can pass throughunhindered. In various embodiments, the projections 162 can be formedwithout apertures and the open area can be due to the interstitialfiber-to-fiber spacing. In various embodiments, the projections 162 canhave less than about 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, or 0.1%open area in a chosen area of the laminate web 160 as measured accordingto the Method to Determine Percent Open Area test method describedherein.

In various embodiments, the shapes of the projections 162, when viewedfrom above, may be, for example, round, oval, square, rectangular,triangular, diamond-shaped, etc. Both the width and the height of theprojections 162 can be varied as can be the spacing and pattern of theprojections 162. In an embodiment, the projections 162 can have aheight, measured according to the Method for Determining Height ofProjections test method described herein, of greater than about 1 mm. Invarious embodiments, the projections 162 can have a height greater thanabout 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 mm. In various embodiments, theprojections 162 can have a height from about 1, 2, 3, 4, or 5 mm toabout 6, 7, 8, 9, or 10 mm.

The projections 162 of the laminate web 160 can be located on andemanate from the outer surface 176 of the projection layer 166. Invarious embodiments, the projections 162 can extend from the outersurface 176 of the projection layer 166 in a direction away from thesupport layer 164. In various embodiments in which the projections 162can be hollow, they can have open ends 186 which can be located towardsthe inner surface 174 of the projection layer 166 and can be covered bythe second surface 170 of the support layer 164 or the inner surface 174of the projection layer 166 depending upon the amount of fiber that hasbeen used from the projection layer 166 to form the projections 162. Theprojections 162 can be surrounded by land areas 188 which can be formedfrom the outer surface 176 of the projection layer 166 though thethickness of the land areas 188 can be comprised of both the projectionlayer 166 and the support layer 164. The land areas 188 can berelatively flat and planar or topographical variability may be builtinto the land areas 188. For example, in various embodiments, a landarea 188 may have a plurality of three-dimensional shapes formed into itby forming the projection layer 166 on a three-dimensionally-shapedforming surface such as is disclosed in U.S. Pat. No. 4,741,941 toEngelbert, et al. and incorporated herein by reference in its entiretyfor all purposes. For example, in various embodiments, a land area 188may be provided with depressions 190 which can extend all or part wayinto the projection layer 166 and/or support layer 164. In addition, aland area 188 may be subjected to embossing which can impart surfacetexture and other functional attributes to the land area 188. In variousembodiments, a land area 188 and the laminate web 160 as a whole may beprovided with apertures 192 which can extend through the laminate web160 so as to further facilitate the movement of body exudate into andthrough the laminate web 160. Such apertures 192 are to be distinguishedfrom interstitial fiber-to-fiber spacing, which is the spacing from oneindividual fiber to the next individual fiber.

In various embodiments, the land areas 188 can have a percentage of openarea in which light can pass through the land areas 188 unhindered bythe material forming the land areas 188, such as, for example, fibrousmaterial. The percentage of open area present in the land areas 188encompasses all area of the land areas 188 where light can pass throughthe land areas 188 unhindered. Thus, for example, the percentage of openarea of a land area 188 can encompass all open area of the land areas188 via apertures, interstitial fiber-to-fiber spacing, and any otherspacing within the land areas 188 when light can pass throughunhindered. In various embodiments, the land areas 188 can have greaterthan about 1% open area in a chosen area of laminate web 160, asmeasured according to the Method to Determine Percent Open Area testmethod described herein. In various embodiments, the land areas 188 canbe formed without apertures and the open area can be due to theinterstitial fiber-to-fiber spacing. In various embodiments, the landareas 188 can have greater than about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,12, 13, 14, 15, 16, 17, 18, 19, or 20% open area in a chosen area of thelaminate web 160. In various embodiments, the land areas 188 can haveabout 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9,9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 14, 14.5, 15, 15.5, 16,16.5, 17, 17.5, 18, 18.5, 19, 19.5, or 20% open area in a chosen area ofthe laminate web 160. In various embodiments, the land areas 188 canhave from about 1, 2, or 3% to about 4 or 5% open area in a chosen areaof the laminate web 160. In various embodiments, the land areas 188 canhave from about 5, 6, or 7% to about 8, 9, or 10% open area in a chosenarea of the laminate web 160. In various embodiments, the land areas 188can have from about 10, 11, 12, 13, 14, or 15% to about 16, 17, 18, 19,or 20% open area in a chosen area of the laminate web 160. In variousembodiments, the land areas can have greater than about 20% open area ina chosen area of the laminate web 160.

The projections 162 of the laminate web 160 can be provided in anyorientation as deemed suitable. In various embodiments, the projections162 of the laminate web 160 can be provided randomly to the laminate web160. In various embodiments, the projections 162 can be orientedlinearly in the longitudinal direction (X) of the absorbent article 10.In various embodiments, the projections 162 can be oriented linearly inthe transverse direction (Y) of the absorbent article 10. In variousembodiments, the projections 162 can be oriented linearly in a directionwhich can be at an angle to the longitudinal direction (X) and/or thetransverse direction (Y) of the absorbent article 10. The land areas 188of the laminate web 160 can be provided in any orientation as deemedsuitable. In various embodiments, the land areas 188 can be orientedlinearly in the longitudinal direction (X) of the absorbent article 10.In various embodiments, the land areas 188 can be oriented linearly inthe transverse direction (Y) of the absorbent article 10. In variousembodiments, the land areas 188 can be oriented linearly in a directionwhich can be at an angle to the longitudinal direction (X) and thetransverse direction (Y) of the absorbent article 10.

In various embodiments, the projections 162 and/or the land areas 188can be provided such that the projections 162 are located in the centralregion 16 of the absorbent article 10, are located towards the perimeterof the absorbent article 10, and combinations thereof. In variousembodiments, the projections 162 can have varying heights in differentareas of the absorbent article 10. In such embodiments, for example, theprojections 162 can have a first height in an area of the absorbentarticle 10 and a different height in a different area of the absorbentarticle 10. In various embodiments, the projections 162 can have varyingdiameters in different areas of the absorbent article 10. In suchembodiments, for example, the projections 162 can have a first diameterin an area of the absorbent article 10 and can have a different diameterin another area of the absorbent article 10. In various embodiments, theconcentration of projections 162 can vary in the absorbent article 10.In such embodiments, an area of the absorbent article 10 can have ahigher concentration of projections 162 than the concentration ofprojections 162 in a second area of the absorbent article 10.

While it is possible to vary the density and fiber content of theprojections 162, in various embodiments, the projections 162 can be“hollow.” When the projections 162 are hollow, they can have a shell 194formed from the fibers of the projection layer 166. The shell 194 candefine an interior space 196 which can have a lower density of fibers ascompared to the shell 194 of the projections 162. By “density” it ismeant the fiber count or content per chosen unit of volume within aportion of the interior space 196 or the shell 194 of the projection162. The density of the shell 194 may vary within a particular orindividual projection 162 and it also may vary as between differentprojections 162. In addition, the size of the hollow interior space 196as well as its density may vary within a particular or individualprojection 162 and it also may vary as between different projections162. If there is at least some portion of an interior space 196 of aprojection 162 that has a lower fiber density than at least some portionof the shell 194 of the same projection 162, then the projection 162 isregarded as being “hollow”. In this regard, in some situations, theremay not be a well-defined demarcation between the shell 194 and theinterior space 196 of the projection 162 but, if with sufficientmagnification of a cross-section of one of the projections 162, it canbe seen that at least some portion of the interior space 196 of theprojection 162 has a lower density than some portion of the shell 194 ofthe same projection 162, then the projection 162 is regarded as being“hollow”, If at least a portion of the projections 162 of a laminate web160 are hollow, the projection layer 166 and the laminate web 160 areregarded as being “hollow” or as having “hollow projections”. In variousembodiments, the portion of the projections 162 which are hollow can begreater than or equal to about 50 percent of the projections 162 in achosen area of the laminate web 160. In various embodiments, greaterthan or equal to about 70 percent of the projections 162 in a chosenarea of the laminate web 160 can be hollow. In various embodiments,greater than or equal to about 90 percent of the projections 162 in achosen area of the laminate web 160 can be hollow.

The laminate web 160 can be the result of the movement of the fibers inthe projection layer 166 in one and sometimes two or more directions. Aspreviously noted, the laminate web 160 can be a fluid entangled laminateweb. Referring to FIG. 15 , if the forming surface upon which theprojection layer 166 is placed is solid except for the forming holesused to form the projections 162, then the force of the fluid entanglingstreams hitting and rebounding off the solid surface land areascorresponding to the land areas 188 of the projection layer 166 cancause a migration of fibers adjacent the inner surface 174 of theprojection layer 166 into the support layer 164 adjacent its secondsurface 170. This migration of fibers in the first direction can berepresented by the arrows 198 shown in FIG. 15 . In order to form theprojections 162 extending outwardly from the outer surface 176 of theprojection layer 166, there must be a migration of fibers in a seconddirection as shown by the arrows 200. It is this migration in the seconddirection which causes fibers from the projection layer 166 to move outand away from the outer surface 176 to form the projections 162. Invarious embodiments in which the support layer 164 can be a fibrousnonwoven web, depending on the degree of web integrity and the strengthand dwell time of the fluid jets during the entanglement process, theremay also be movement of support layer 164 fibers into the projectionlayer 166 as shown by arrows 202 in FIG. 15 . The net result of thesefiber movements can be the creation of a laminate web 160 with goodoverall integrity and lamination of the layers (164 and 166) at theirinterface 180 thereby allowing further processing and handling of thelaminate web 160. As a result of the fluid entanglement process tocreate the laminate web 160, it is generally not desirable that thefluid pressure used to form the projections 162 be of sufficient forceso as to force fibers from the support layer 164 to be exposed on theouter surface 176 of the projection layer 166.

The support layer 164 can support the projection layer 166 and can bemade from a number of structures provided the support layer 164 can becapable of supporting the projection layer 166. The primary functions ofthe support layer 164 can be to protect the projection layer 166 duringthe formation of the projections 162, to be able to bond to or beentangled with the projection layer 166 and to aid in further processingof the projection layer 166 and the resultant laminate web 160. Suitablematerials for the support layer 164 can include, but are not limited to,nonwoven fabrics or webs, scrim materials, netting materials,paper/cellulose/wood pulp-based products which can be considered asubset of nonwoven fabrics or webs as well as foam materials, films andcombinations of the foregoing provided the material or materials chosenare capable of withstanding a process of manufacture such as afluid-entangling process. In an embodiment, the support layer 164 can bea fibrous nonwoven web made from a plurality of randomly depositedfibers which may be staple length fibers such as are used, for example,in carded webs, air laid webs, etc. or they may be more continuousfibers such as are found in, for example, meltblown or spunbond webs.Due to the functions the support layer 164 must perform, the supportlayer 164 can have a higher degree of integrity than the projectionlayer 166. In this regard, the support layer 164 can remainsubstantially intact when it is subjected to a fluid-entangling process.The degree of integrity of the support layer 164 can be such that thematerial forming the support layer 164 can resist being driven down intoand filling the projections 162 of the projection layer 166. As aresult, in an embodiment in which the support layer 164 is a fibrousnonwoven web, it should have a higher degree of fiber-to-fiber bondingand/or fiber entanglement than the fibers in the projection layer 166.While it can be desirable to have fibers from the support layer 164entangle with the fibers of the projection layer 166 adjacent theinterface 180 between the two layers, it is generally desired that thefibers of this support layer 164 not be integrated or entangled into theprojection layer 166 to such a degree that large portions of thesefibers find their way inside the projections 162.

In order to resist the higher degree of fiber movement, as mentionedabove, in an embodiment, the support layer 164 can have a higher degreeof integrity than the projection layer 166. This higher degree ofintegrity can be brought about in a number of ways. One can befiber-to-fiber bonding which can be achieved through thermal orultrasonic bonding of the fibers to one another with or without the useof pressure as in through-air bonding, point bonding, powder bonding,chemical bonding, adhesive bonding, embossing, calender bonding, etc. Inaddition, other materials may be added to the fibrous mix such asadhesives and/or bicomponent fibers. Pre-entanglement of a fibrousnonwoven support layer 164 may also be used such as, for example, bysubjecting the web to hydroentangling, needlepunching, etc., prior tothis support layer 164 being joined to a projection layer 166.Combinations of the foregoing are also possible. Still other materialssuch as foams, scrims and nettings may have enough initial integrity soas to not need further processing. The level of integrity can in manycases be visually observed due to, for example, the observation with theunaided eye of such techniques as point bonding which is commonly usedwith fibrous nonwoven webs such as spunbond webs and staplefiber-containing webs. Further magnification of the support layer 164may also reveal the use of fluid-entangling or the use of thermal and/oradhesive bonding to join the fibers together. Depending on whethersamples of the individual layers (164 and 166) are available, tensiletesting in either or both of the machine and cross-machine directionsmay be undertaken to compare the integrity of the support layer 164 tothe projection layer 166. See for example ASTM test D5035-11 which isincorporated herein its entirety for all purposes.

The type, basis weight, tensile strength and other properties of thesupport layer 164 can be chosen and varied depending upon the particularend use of the resultant laminate web 160. When the laminate web 160 isto be used as part of a personal care absorbent article, it can begenerally desirable that the support layer 164 be a layer that is fluidpervious, has good wet and dry strength, is able to absorb fluids suchas body exudates, possibly retain the fluids for a certain period oftime and then release the fluids to one or more subjacent layers. Inthis regard, fibrous nonwovens such as spunbond webs, meltblown webs andcarded webs such as airlaid webs, bonded carded webs and coformmaterials are well-suited as support layers 164. Foam materials andscrim materials are also well-suited. In addition, the support layer 164may be a multi-layered material due to the use of several layers or theuse of multi-bank formation processes as are commonly used in makingspunbond webs and meltblown webs as well as layered combinations ofmeltblown and spunbond webs. In the formation of such support layers164, both natural and synthetic materials may be used alone or incombination to fabricate the materials. In various embodiments, thesupport layer 164 can have a basis weight ranging from about 5 to about40 or 50 gsm.

The type, basis weight and porosity of the support layer 164 can affectthe process conditions necessary to form the projections 162 in theprojection layer 166. Heavier basis weight materials can increase theentangling force of the entangling fluid streams needed to form theprojections 162 in the projection layer 166. However, heavier basisweight support layers 164 can also provide improved support for theprojection layer 166 as the projection layer 166 by itself can be toostretchy to maintain the shape of the projections 162 post the formationprocess. The projection layer 164 by itself can unduly elongate in themachine direction due to the mechanical forces exerted on it bysubsequent winding and converting processes and consequently diminishand distort the projections. Also, without the support layer 164, theprojections 162 in the projection layer 166 tend to collapse due to thewinding pressures and compressive weights the projection layer 166experiences in the winding process and subsequent conversion and do notrecover to the extent they do when a support layer 164 is present.

The support layer 164 may be subjected to further treatment and/oradditives to alter or enhance its properties. For example, surfactantsand other chemicals may be added both internally and externally to thecomponents forming all or a portion of the support layer 164 to alter orenhance its properties. Compounds commonly referred to as hydrogels orsuperabsorbents which absorb many times their weight in liquids may beadded to the support layer 164 in both particulate and fiber form.

The projection layer 166 can be made from a plurality of randomlydeposited fibers which may be staple length fibers such as are used, forexample, in carded webs, airlaid webs, coform webs, etc., or they may bemore continuous fibers such as are found in, for example, meltblown orspunbond webs. The fibers in the projection layer 166 can have lessfiber-to-fiber bonding and/or fiber entanglement and thus less integrityas compared to the integrity of the support layer 164, especially inembodiments when the support layer 164 is a fibrous nonwoven web. In anembodiment, the fibers in the projection layer 166 may have no initialfiber-to-fiber bonding for purposes of allowing the formation of theprojections 162. Alternatively, when both the support layer 164 and theprojection layer 166 can both be fibrous nonwoven webs, the projectionlayer 166 can have less integrity than the support layer 164 due to theprojection layer 166 having, for example, less fiber-to-fiber bonding,less adhesive or less pre-entanglement of the fibers forming theprojection layer 166.

The projection layer 166 can have a sufficient amount of fiber movementcapability to allow a fluid entangling process to be able to move afirst plurality of the plurality of fibers of the projection layer 166out of the X-Y plane of the projection layer 166 and into theperpendicular or Z-direction of the projection layer 166 so as to beable to form the projections 162. As noted herein, in variousembodiments, the projections 162 can be hollow. In an embodiment, asecond plurality of the plurality of fibers in the projection layer 166can become entangled with the support layer 164. If more continuousfiber structures are being used such as meltblown or spunbond webs, inan embodiment, there may be little or no pre-bonding of the projectionlayer 166 prior to the fluid entanglement process. Longer fibers such asare generated in meltblowing and spunbonding processes (which are oftenreferred to as continuous fibers to differentiate them from staplelength fibers) will typically require more force to displace the fibersin the Z-direction than will shorter, staple length fibers thattypically have fiber lengths less than about 100 mm and more typicallyfibers lengths in the 10 to 60 mm range. Conversely, staple fiber webssuch as carded webs and airlaid webs can have some degree of pre-bondingor entanglement of the fibers due to their shorter length. Such shorterfibers require less fluid force from the fluid entangling streams tomove them in the Z-direction to form the projections 162. As a result, abalance must be met between fiber length, degree of pre-fiber bonding,fluid force, web speed and dwell time so as to be able to create theprojections 162 without, unless desired, forming apertures in the landareas 188 or the projections 162 or forcing too much material into theinterior space 196 of the projections 162 thereby making the projections162 too rigid for some end-use applications.

In various embodiments, the projection layer 166 can have a basis weightranging from about 10 gsm to about 60 gsm. Spunbond webs can typicallyhave basis weights of between about 15 and about 50 gsm when being usedas the projection layer 166. Fiber diameters can range between about 5and about 20 microns. The fibers may be single component fibers formedfrom a single polymer composition or they may be bicomponent ormulticomponent fibers wherein one portion of the fiber can have a lowermelting point than the other components so as to allow fiber-to-fiberbonding through the use of heat and/or pressure. Hollow fibers may alsobe used. The fibers may be formed from any polymer formulationstypically used to form spunbond webs. Examples of such polymers include,but are not limited to, polypropylene (“PP”), polyester (“PET”),polyamide (“PA”), polyethylene (“PE”) and polylactic acid (“PLA”). Thespunbond webs may be subjected to post-formation bonding and entanglingtechniques if necessary to improve the processability of the web priorto its being subjected to the projection forming process.

Meltblown webs can typically have basis weights of between about 20 andabout 50 gsm when being used as the projection layer 166. Fiberdiameters can range between about 0.5 and about 5 microns. The fibersmay be single component fibers formed from a single polymer compositionor they may be bicomponent or multicomponent fibers wherein one portionof the fiber can have a lower melting point than the other components soas to allow fiber-to-fiber bonding through the use of heat and/orpressure. The fibers may be formed from any polymer formulationstypically used to form spunbond webs. Examples of such polymers include,but are not limited to, PP, PET, PA, PE and PLA.

Carded and airlaid webs can use staple fibers that can typically rangein length between about 10 and about 100 millimeters. Fiber denier canrange between about 0.5 and about 6 denier depending upon the particularend use. Basis weights can range between about 20 and about 60 gsm. Thestaple fibers may be made from a wide variety of polymers including, butnot limited to, PP, PET, PA, PE, PLA, cotton, rayon, flax, wool, hempand regenerated cellulose such as, for example, Viscose. Blends offibers may be utilized too, such as blends of bicomponent fibers andsingle component fibers as well as blends of solid fibers and hollowfibers. If bonding is desired, it may be accomplished in a number ofways including, for example, through-air bonding, calender bonding,point bonding, chemical bonding and adhesive bonding such as powderbonding. If needed, to further enhance the integrity and processabilityof a projection layer 166 prior to the projection forming process, theprojection layer 166 may be subjected to pre-entanglement processes toincrease fiber entanglement within the projection layer 166 prior to theformation of the projections 162. Hydroentangling can be advantageous inthis regard.

Examples of a laminate web 160 and process for manufacturing a laminateweb 160 can be found in U.S. Pat. No. 9,474,660 to Kirby et al. which ishereby incorporated by reference in its entirety.

Absorbent Core:

An absorbent core 38 can be positioned between the topsheet layer 30 andthe liquid impermeable layer 36 of the absorbent article 10. Theabsorbent core 38 can generally be any single layer structure orcombination of layer components, which can demonstrate some level ofcompressibility, conformability, be non-irritating to the wearer's skin,and capable of absorbing and retaining liquids and other body exudates.In various embodiments, the absorbent core 38 can be formed from avariety of different materials and can contain any number of desiredlayers. For example, the absorbent core 38 can include one or morelayers (e.g., two layers) of absorbent web material of cellulosic fibers(e.g., wood pulp fibers), other natural fibers, synthetic fibers, wovenor nonwoven sheets, scrim netting, or other stabilizing structures,superabsorbent material, binder materials, surfactants, selectedhydrophobic and hydrophilic materials, pigments, lotions, odor controlagents or the like, as well as combinations thereof. In an embodiment,the absorbent web material can include a matrix of cellulosic fluff andcan also include superabsorbent material. The cellulosic fluff cancomprise a blend of wood pulp fluff. An example of wood pulp fluff canbe identified with the trade designation NB416, available fromWeyerhaeuser Corp., and is a bleached, highly absorbent wood pulpcontaining primarily soft wood fibers.

In various embodiments, if desired, the absorbent core 38 can include anoptional amount of superabsorbent material. Examples of suitablesuperabsorbent material can include poly(acrylic acid), poly(methacrylicacid), poly(acrylamide), poly(vinyl ether), maleic anhydride copolymerswith vinyl ethers and α-olefins, poly(vinyl pyrrolidone),poly(vinylmorpholinone), poly(vinyl alcohol), and salts and copolymersthereof. Other superabsorbent materials can include unmodified naturalpolymers and modified natural polymers, such as hydrolyzedacrylonitrile-grafted starch, acrylic acid grafted starch, methylcellulose, chitosan, carboxymethyl cellulose, hydroxypropyl cellulose,and natural gums, such as alginates, xanthan gum, locust bean gum, andso forth. Mixtures of natural and wholly or partially syntheticsuperabsorbent polymers can also be useful. The superabsorbent materialcan be present in the absorbent core 38 in any amount as desired.

Regardless of the combination of absorbent materials used in theabsorbent core 38, the absorbent materials can be formed into a webstructure by employing various conventional methods and techniques. Forexample, the absorbent web can be formed by techniques such as, but notlimited to, a dry-forming technique, an air forming technique, a wetforming technique, a foam forming technique, or the like, as well ascombinations thereof. A coform nonwoven material can also be employed.Methods and apparatus for carrying out such techniques are well known inthe art.

The shape of the absorbent core 38 can vary as desired and can compriseany one of various shapes including, but not limited to, triangular,rectangular, dog-bone, elliptical, trapezoidal, T-shape, I-shape, andhourglass shapes. In various embodiments, the absorbent core 38 can havea shape that generally corresponds with the overall shape of theabsorbent article 10. The dimensions of the absorbent core 38 can besubstantially similar to those of the absorbent article 10, however, itwill be appreciated that the dimensions of the absorbent core 38 whilesimilar, will often be less than those of the overall absorbent article10, in order to be adequately contained therein. The size and theabsorbent capacity of the absorbent core 38 should be compatible withthe size of the intended wearer and the liquid loading imparted by theintended use of the absorbent article 10. Additionally, the size and theabsorbent capacity of the absorbent core 38 can be varied to accommodatewearers ranging from infants to adults.

The absorbent core 38 can have a length ranging from about 120, 125,130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 225, 230, 240, 250,260, 270, 280, 290, 300, 310, 320, 330, 340, or 350 mm to about 355,360, 380, 385, 390, 395, 400, 410, 415, 420, 425, 440, 450, 460, 480,500, 510, 520, 530, 540, 550, 600, 610, 620, or 630 mm. The absorbentcore 38 may have a width in the central region 16 ranging from about 30,40, 50, 55, 60, 65, or 70 mm to about 75, 80, 85, 90, 95, 100, 105, 110,115, 120, 125, 130, 140, 150, 160, 170 or 180 mm. The width of theabsorbent core 38 located within the anterior region 12 and/or posteriorregion 14 of the absorbent article 10 may range from about 50, 55, 60,65, 70, 75, 80, 85, 90, or 95 mm to about 100, 105, 110, 115, 120, 125or 130 mm. As noted herein, the absorbent core 38 can have a length andwidth that can be less than or equal to the length and width of theabsorbent article 10.

In an embodiment, the absorbent article 10 can be a diaper having thefollowing ranges of lengths and widths of an absorbent core 38 having anhourglass shape: the length of the absorbent core 38 may range fromabout 170, 180, 190, 200, 210, 220, 225, 240 or 250 mm to about 260,280, 300, 310, 320, 330, 340, 350, 355, 360, 380, 385, or 390 mm; thewidth of the absorbent core 38 in the central region 16 may range fromabout 40, 50, 55, or 60 mm to about 65, 70, 75, or 80 mm; the width ofthe absorbent core 38 in the anterior region 12 and/or the posteriorregion 14 may range from about 80, 85, 90, or 95 mm to about 100, 105,or 110 mm.

In an embodiment, the absorbent article 10 may be a training pant oryouth pant having the following ranges of lengths and widths of anabsorbent core 38 having an hourglass shape: the length of the absorbentcore 38 may range from about 400, 410, 420, 440 or 450 mm to about 460,480, 500, 510 or 520 mm; the width of the absorbent core 38 in thecentral region 16 may range from about 50, 55, or 60 mm to about 65, 70,75, or 80 mm; the width of the absorbent core 38 in the anterior region12 and/or the posterior region 14 may range from about 80, 85, 90, or 95mm to about 100, 105, 110, 115, 120, 125, or 130 mm.

In an embodiment, the absorbent article 10 can be an adult incontinencegarment having the following ranges of lengths and widths of anabsorbent core 38 having a rectangular shape: the length of theabsorbent core 38 may range from about 400, 410 or 415 to about 425 or450 mm; the width of the absorbent core 38 in the central region 16 mayrange from about 90, or 95 mm to about 100, 105, or 110 mm. It should benoted that the absorbent core 38 of an adult incontinence garment may ormay not extend into either or both the anterior region 12 or theposterior region 14 of the absorbent article 10.

By way of example, suitable materials and/or structures for theabsorbent core 38 can include, but are not limited to, those describedin U.S. Pat. No. 4,610,678 to Weisman, et al., U.S. Pat. No. 6,060,636to Yahiaoui, et al., U.S. Pat. No. 6,610,903 to Latimer, et al., U.S.Pat. No. 7,358,282 to Krueger, et al., and U.S. Publication No.2010/0174260 to Di Luccio, et al. each of which is hereby incorporatedby reference thereto in its entirety.

In various embodiments, an absorbent core 38 can be a single layerstructure and can include, for example, a matrix of cellulosic fluff andsuperabsorbent material. In various embodiments, an absorbent core 38can have at least two layers of material, such as, for example, a bodyfacing layer and a garment facing layer. In various embodiments, the twolayers can be identical to each other. In various embodiments, the twolayers can be different from each other. In such embodiments, the twolayers can provide the absorbent article 10 with different absorptionproperties as deemed suitable. In various embodiments, the body facinglayer of the absorbent core 38 may be constructed of an airlaid materialand the garment facing layer of the absorbent core 38 may be constructedof a superabsorbent polymer-containing compressed sheet. In suchembodiments, the airlaid material can have a basis weight from about 40to about 200 gsm and the superabsorbent polymer-containing compressedsheet can be a cellulosic fluff based material that can be a combinationof cellulosic pulp and SAP enclosed with a tissue carrier and having abasis weight from about 40 to about 400 gsm.

Liquid Impermeable Layer:

The liquid impermeable layer 36 is generally liquid impermeable and isthe portion of the absorbent article 10 which faces the garments of thewearer. The liquid impermeable layer 36 can permit the passage of air orvapor out of the absorbent article 10 while still blocking the passageof liquids. Any liquid impermeable material may generally be utilized toform the liquid impermeable layer 36. The liquid impermable layer 36 canbe composed of a single layer or multiple layers, and these one or morelayers can themselves comprise similar or different materials. Suitablematerial that may be utilized can be a microporous polymeric film, suchas a polyolefin film or polyethylene or polypropylene, nonwovens, andnonwoven laminates, and film/nonwoven laminates. The particularstructure and composition of the liquid impermeable layer 36 can beselected from various known films and/or fabrics with the particularmaterial being selected as appropriate to provide the desired level ofliquid barrier, strength, abrasion resistance, tactile properties,aesthetics, and so forth. In various embodiments, a polyethylene filmcan be utilized that can have a thickness in the range of from about 0.2or 0.5 mils to about 3.0 or 5.0 mils. An example of a liquid impermeablelayer 36 can be a polyethylene film such as that obtainable from PliantCorp., Schaumburg, Ill., USA. Another example can include calciumcarbonate-filled polypropylene film. In still another embodiment, theliquid impermeable layer 36 can be a hydrophobic nonwoven material withwater barrier properties such as a nonwoven laminate, an example ofwhich can be a spunbond, meltblown, meltblown, spunbons, four-layeredlaminate.

In various embodiments, the liquid impermeable layer 36 can be a twolayer construction, including an outer layer material and an inner layermaterial which can be bonded together. The outer layer can be anysuitable material and may be one that provides a generally cloth-liketexture or appearance to the wearer. An example of such material can bea 100% polypropylene bonded-carded web with a diamond bond patternavailable from Sandler A. G., Germany, such as 30 gsm Sawabond 4185® orequivalent. Another example of material suitable for use as an outerlayer can be a 20 gsm spunbond polypropylene non-woven web. The innerlayer can be either vapor permeable (i.e., “breathable”) or vaporimpermeable. The inner layer may be manufactured from a thin plasticfilm, although other liquid impermeable materials may also be used. Theinner layer can inhibit liquid body exudates from leaking out of theabsorbent article 10 and wetting articles, such as bed sheets andclothing, as well as the wearer and caregiver. An example of a materialfor an inner layer can be a printed 19 gsm Berry Plastics XP-8695H filmor equivalent commercially available from Berry Plastics Corporation,Evansville, Ind., U.S.A.

The liquid impermeable layer 36 can, therefore, be of a single ormultiple layer construction, such as of multiple film layers orlaminates of film and nonwoven fibrous layers. Suitable liquidimpermeable layers 36 can be constructed from materials such as thosedescribed in U.S. Pat. No. 4,578,069 to Whitehead, et al., U.S. Pat. No.4,376,799 to Tusim, et al., U.S. Pat. No. 5,695,849 to Shawver, et al.,U.S. Pat. No. 6,075,179 to McCormack, et al., and U.S. Pat. No.6,376,095 to Cheung, et al., each of which are hereby incorporated byreference thereto in its entirety.

Exudate Management Layer:

In various embodiments, the absorbent article 10 can have an exudatemanagement layer 40 in fluid communication with the topsheet layer 30.In various embodiments, such as, for example, illustrated in FIGS. 3, 4,8, and 9 , the exudate management layer 40 can be positioned on the bodyfacing surface 32 of the topsheet layer 30. In various embodiments, suchas, for example, illustrated in FIGS. 5, 6, 10, and 11 , the exudatemanagement layer 40 can be positioned between the topsheet layer 30 andthe absorbent core 38.

In various embodiments, the exudate management layer 40 can be made of amaterial that can be capable of transferring, in the depth direction(Z), body exudates that are delivered to the topsheet layer 30. Any of avariety of materials can be utilized as the exudate management layer 40.In various embodiments, the material can be synthetic, cellulosic, or acombination of synthetic and cellulosic materials. In variousembodiments, the exudate management layer 40 can be constructed fromwoven or nonwoven materials. For example, the exudate management layer40 can be constructed as an airlaid or a TABCW material. For example,airlaid cellulosic tissues may be suitable for use in the exudatemanagement layer 40. The airlaid cellulosic tissue may have a basisweight ranging from about 10 or 100 gsm to about 250 or 300 gsm. Theairlaid cellulosic tissue can be formed from hardwood and/or softwoodfibers. An airlaid cellulosic tissue can have a fine pore structure andcan provide an excellent wicking capacity.

In various embodiments, a foam material can be utilized to form theexudate management layer 40. In various embodiments, the foam materialcan be an open-cell or porous foam. The physical properties of the foammaterial as well as its wettability and fluid management properties canbe tailored to meet the specific characteristics desired for the usageof a foam material in the absorbent article 10. In various embodiments,the foam material can be moisture stable and not degrade or collapse andlose its structure and fluid management properties when exposed to bodyexudate. In various embodiments, the foam material can be an open-cellfoam, a closed cell foam, or a partially open-cell foam that is either athermoplastic or thermoset material. A foam material can be manufacturedby extrusion or casting and coating processes including frothed foam,aerated foam, and emulsion foam methods. Such foams can be manufacturedfrom different polymer chemistries to achieve the desired softness,flexibility, and resilience of the foam material when utilized in anabsorbent article 10. In various embodiments, the foam material can bebased on organic or inorganic chemistries and can also be based upon afoam material obtained from natural sources. In various embodiments, thefoam material can have a polymer chemistry which can be a polyurethanefoam, polyolefin foam, poly(styrene-butadiene) foam, poly(ethylene-vinylacetate) foam, or a silicone based foam. Other polymer chemistries knownto one of ordinary skill in the art could be used along with additivessuch as plasticizers, opacifiers, colorants, antioxidants, andstabilizers to obtain the desired foam properties. In variousembodiments, the viscoelastic properties could be modified to obtain adesired response to applied load from the foam material includingproperties similar to that commonly referred to as polyurethane memoryfoam materials. In various embodiments, the Poisson's ratio of the foammaterial could be modified to obtain the desired response from the foammaterial to applied stress and foam materials with auxetic propertiescould be considered if desired.

In various embodiments in which a foam material is utilized for theexudate management layer, the foam material can have material propertiesto enable cutting of the foam material such as, for example, with amechanical die, such as foam materials which are referred to asclickable foams in the polyurethane foam industry. In variousembodiments, the foam material can also be selected to enable othermethods of cutting the foam material including, but not limited to,laser die cutting and water jet cutting. In various embodiments, thefoam material can be tailored to enable perforating the foam materialutilizing mechanical dies and cutting or hole-punching devices and canalso be capable of achieving the perforation utilizing ultrasonicprocesses.

A porous foam material can have pores which can vary in size and/ordistribution. In various embodiments, a pore size of a foam material canbe from about 10 microns to about 350 microns. In various embodiments,the foam material can have a multimodal pore size distribution in orderto handle a variety of components within the body exudates. In variousembodiments, a multimodal pore size distribution can be achieved withinthe same monolithic foam structure or could be achieved by using layersof foam material with a narrow pore size distribution which whencombined into a single foam material would allow a multimodal pore sizedistribution to be achieved for the combination of layers.

In various embodiments, the foam material can be a polyesterpolyurethane foam material. In various embodiments, the average cellsize of the foam material can be from about 100, 150, or 200 microns toabout 250, 300, or 350 microns. The number of open cells in the foammaterial can provide the foam material with measurement of the foammaterial's porosity. The porosity of the foam material is measured inpores per linear inch (ppi) and refers to the number of pores in onelinear inch of a two-dimensional planar foam material surface and isdescribed by the Polyurethane Foam Association. The pores per linearinch is measured by counting the pores visually under a microscope usinga grid. The smaller the ppi value of the foam material the larger thepore size, and vice versa. In various embodiments, the foam material canhave a porosity from about 20 or 40 ppi to about 55, 65, or 90 ppi. Invarious embodiments in which an open-cell foam material is utilized, thefoam material can be substantially open-cell or of a completelyreticulated structure. The reticulation of the foam material can beachieved by several methods known to one skilled in the art include foammade by in-situ reticulation processes during foam formation. Thereticulated foam material can also be made by treating a substantiallyopen-cell foam material to a high pressure fluid stream to remove thecell walls of the foam material. In general, foam materials are capableof stretching, however, in various embodiments the foam material canhave a reduced elongation capacity. In various embodiments, the foammaterial can have a low elongation, such as, for example, less than a200% elongation at break. In various embodiments, the foam material hasan elongation at break from about 80 or 100% to about 150 or 200%. Invarious embodiments, the basis weight of the foam material can be fromabout 45 gsm to about 50 or 55 gsm. In various embodiments, the densityof the foam material can be from about 0.01, 0.02 or 0.03 g/cc to about0.05 or 0.08 g/cc. The foam material can also have a compression modulusthat allows it to be soft and flexible when used in an absorbentarticle. In various embodiments, the foam material can have acompression force deflection at 25% deflection from about 0.5 or 0.6 psito about 0.8 or 1.0 psi.

The foam material can be either hydrophilic or hydrophobic dependentupon the desired properties of the foam material in the absorbentarticle 10. In various embodiments the foam material can be ahydrophilic foam material. In various embodiments, the foam material canbe hydrophobic and can be treated with a surfactant to create ahydrophilic foam material. In various embodiments, for example, thematerial utilized to form the exudate management layer 40 can be ahydrophobic, open-cell, polyurethane foam treated with from about 0.3%or 0.8% to about 1.6, 2.0, or 3.0% of a surfactant. In variousembodiments, the surfactant utilized to treat the foam material can be anonionic surfactant such as a nonionic surfactant comprising at least anethoxylated linear oleochemical alcohol such as an alkylphenolethoxylate, such as LUTENSOL® A65N, commercially available from BASF, oran ethoxylated acetylenic diol such as SURFYNOL® 465, commerciallyavailable from Air Products, Allentown, Pa. In various embodiments, thehydrophilicity of the foam material, as a result of the surfactanttreatment, can be uniform in the longitudinal direction (X) and thetransverse direction (Y) of the foam material. In various embodiments,the hydrophilicity of the foam material, as a result of the surfactanttreatment, can vary in the longitudinal direction (X), in the transversedirection (Y), or in both of the longitudinal direction (X) and thetransverse direction (Y). In various embodiments, the polymer utilizedto formulate the foam material can be selected to have the desiredhydrophilic properties. In various embodiments, this can be achieved byusing an inherently hydrophilic polymer that is wettable by aqueousfluids or by including additives in the polymer during formation of thefoam material. These additives can make the foam material wettable toaqueous fluids even if the base polymer of the foam material ishydrophobic. A non-limiting example of such an approach can be toinclude polyethylene glycol as an additive with a hydrophobic polymer.

In various embodiments, the foam material can be hydrophobic and canhave hydrophilic fibers inserted into the foam material to create ahydrophilic foam and fiber composite. The hydrophilic fibers within thefoam material can provide a hydrophilic pathway through the foammaterial to direct body exudates through the foam material. Referring toFIGS. 16, 17, and 18 , FIG. 16 is a photomicrograph (taken by scanningelectron microscope at a magnification of 100×) of a cross-sectionalview of a portion of a foam and fiber composite material 100 suitablefor use as the exudate management layer 40, FIG. 17 is a photomicrograph(taken by scanning electron microscope at a magnification of 40×) of aplanar view of the foam and fiber composite material 100 of FIG. 16 suchthat the fibrous material is visible to the viewer, and FIG. 18 is aphotomicrograph (taken by scanning electron microscope at amagnification of 40×) of a planar view of the foam and fiber composite100 of FIG. 16 such that the second planar surface of the foam materialand portions of fibers are visible to the viewer.

As is visible in FIGS. 16, 17, and 18 , the foam and fiber compositematerial 100 can be formed of an open-cell foam material 110 and afibrous material 120. The foam material 110 can have a first planarsurface 112 and a second planar surface 114. In FIG. 16 , each planarsurface, 112 and 114, have been delineated by the corresponding brokenlines for visual clarity. A layer of fibrous material 120 is in contactwith one of the planar surfaces, such as planar surface 112, of the foammaterial 110. The layer of fibrous material 120 is formed from aplurality of individual fibers 122. As is visible in the foam and fibercomposite material 100 shown in FIG. 16 , a portion of the individualfibers 122 can extend from the fibrous material 120 and through the foammaterial 110 from the first planar surface 112 of the foam material 110to the second planar surface 114 of the foam material 110. The foam andfiber composite 100 can have a total basis weight from about 20 gsm toabout 250 gsm. The amount of fibrous material 120, including individualfibers 122 which are within the foam material, is at least about 10% ofthe total basis weight of the foam and fiber composite 100. In variousembodiments, at least about 2, 5, 10, 15, 20, 30, 40, 50, 60 or 70 gsmof fibrous material 120 is brought into contact with a planar surface,such as planar surface 112 of the foam material 110.

In various embodiments, the fibrous material 120 can be formed from aplurality of individual fibers 122. In various embodiments, theindividual fibers 122 of the fibrous material 120 can be a looseconfiguration such as may occur with wet-laying or air-laying of thefibrous material 120. In various embodiments, the individual fibers 122of the fibrous material 120 can be in the form of a nonwoven web ofmaterial such as, for example, a carded nonwoven web. The fibrousmaterial 120 can, therefore, be manufactured via various processes suchas, but not limited to, air-laying, wet-laying, and carding. In variousembodiments, the fibers 122 forming the fibrous material 120 can behydrophilic. The fibers 122 can be naturally hydrophilic or can befibers which are naturally hydrophobic but which have been treated to behydrophilic, such as, for example, via a treatment with a surfactant.Providing hydrophilic fibers 122 can allow for a foam and fibercomposite 100 which can have hydrophilic pathways through the foammaterial 110. In various embodiments in which the foam material 110 ishydrophobic, the hydrophilic pathways provided by the hydrophilic fibers122 can allow for the foam and fiber composite 100 in an absorbentarticle 10 to intake bodily exudates (via the hydrophilic fiberpathways) and maintain the body exudates in a location away from thetopsheet layer 30 of the absorbent article 10 as the body exudates willnot be able to readily pass through the hydrophobic foam material 110.

In various embodiments, the fibers 122 forming the fibrous material 120can be cellulosic fibers such as, but not limited to, cotton, ramie,jute, hemp, flax, bagasse, northern softwood kraft pulp, as well assynthetic cellulosic fibers such as, but not limited to, rayon, viscose,and cellulosic acetate. In various embodiments, the fibers 122 formingthe fibrous material 120 can be synthetic fibers made from polymers suchas polyethylene, polypropylene, aromatic polyesters, aliphaticpolyesters, and polyamides. In such embodiments, the fibers 122 can betreated with additives to impart various degrees of surface energyranging from very low surface energy and low wettability to high surfaceenergy and high wettability.

The exudate management layer 40 is formed from a base sheet of material,such as any of the materials described above. The exudate managementlayer 40 can have a first opening 56 and a second opening 58. The firstopening 56 can allow for direct passage of body exudate such as urineinto an absorbent core 38 and the second opening 58 can allow for directpassage of body exudate such as fecal material into the absorbent core38. In various embodiments, the exudate management layer 40 can have afirst component 42 within which each of the first opening 56 and thesecond opening 58 can be positioned. In such embodiments, the firstcomponent 42 can at least partially define each of the first opening 56and the second opening 58. For example, as illustrated in FIGS. 3-7F,the exudate management layer 40 can have a first component 42 withinwhich each of the first opening 56 and the second opening 58 can bepositioned and which are at least partially defined by the firstcomponent 42. In various embodiments, the exudate management layer 40can be configured to have a first component 42 which can at leastpartially define the first opening 56 and a second component 70connected to the first component 42 via a primary fold 72 wherein thesecond component 70 can at least partially define the second opening 58.For example, as illustrated in FIGS. 8-12C, the exudate management layer40 can have a first component 42 which can at least partially define thefirst opening 56 and a second component 70 connected to the firstcomponent 42 via primary fold 72 and which at least partially definesthe second opening 58.

In embodiments in which the exudate management layer 40 has a firstcomponent 42 at least partially defining each of the first opening 56and second opening 58 and in embodiments in which the exudate managementlayer 40 has a first component 42 and a second component 70 connected tothe first component 42 via a primary fold 72, the first component 42 canhave a first transverse direction end edge 44, a second transversedirection end edge 46, and an opposing pair of longitudinal directionside edges 46 extending between and connecting the transverse directionend edges, 44 and 46. The first component 42 can generally have anyshape and/or size desired. In various embodiments, for example, thefirst component 42 can have a rectangular shape, a curved rectangularshape, an oval shape, an elliptical shape, a circular shape, anhourglass shape, a square shape, or a curved square shape. In variousembodiments, each of the edges, 44, 46, and 48, of the first component42 can be straight. In various embodiments, at least one of the edges,44, 46, or 48, of the first component 42 can be arcuate and theremaining edges can be straight. In various embodiments, at least two ofthe edges, 44, 46, or 48, of the first component 42 can be arcuate andthe remaining edges can be straight. In various embodiments, forexample, the longitudinal direction side edges 48 of the first component42 can be straight and the transverse direction end edges, 44 and 46,can be arcuate. In various embodiments, the transverse direction endedges, 44 and 46, can have an arcuate shape which can form acomplementary configuration with each other if the two edges, 44 and 46,were to be brought together. In various embodiments, at least three ofthe edges, 44, 46, or 48, of the first component 42 can be arcuate andthe remaining edge can be straight. In various embodiments, all of theedges, 44, 46, and 48, of the first component 42 can be arcuate.

In various embodiments, the first component 42 can have a longitudinaldirection length as measured from the first transverse direction endedge 44 to the second transverse direction end edge 46 which can be lessthan the overall length of the absorbent article 10. For example, thefirst component 42 can have a longitudinal length between about 20, 30,40, 50, 60, 80, 100, 150, 175, or 200 mm to about 220, 240, 260, 280,300, 320, 340, 360, 380, 400, 420, 440, 460, 480, or 500 mm. In variousembodiments, the first component 42 can have a longitudinal directionlength that is from about 15, 20, 25, 30, 35, or 40% to about 50, 55,60, 65, 70, 75, 80, 85, or 90% of the longitudinal length of theabsorbent article 10. In various embodiments, the first component 42 canhave a transverse width as measured from a first longitudinal directionside edge 48 to a second longitudinal direction side edge 48 which canbe equal to or less than the overall width of the absorbent article 10.For example, the first component 42 can have a transverse width betweenabout 10, 15, 20, 30, 40, 50, 60, 70, or 80 mm to about 90, 100, 110,120, 130, 140, 150, 160, or 170 mm. In various embodiments, the firstcomponent 42 can have a transverse width that is from about 15, 20, 25,30, 35, of 40% to about 50, 55, 60, 65, 70, 75, 80, 85, or 90% of thetransverse width of the absorbent article 10. In various embodiments,the transverse width of the first component 42 can be uniform in thelongitudinal direction of the first component 42. In variousembodiments, the transverse width of the first component 42 can varyalong the longitudinal direction of the first component 42. The firstcomponent 42 has a body facing surface 50 and a garment facing surface52. The first component 42 can provide the exudate management layer 40with a first height dimension 54 in the depth direction (Z) of theexudate management layer 40. In various embodiments, the first heightdimension 54 can be from about 0.5, 0.75, 1, 1.5, 2, or 3.5 mm to about3, 3.5, 4, 4.5, 5, 6, or 10 mm.

In various embodiments, the exudate management layer 40 is configured tohave a first opening 56 for direct passage of body exudates, such asurine, into the absorbent core 38 and a second opening 58 for directpassage of body exudates, such as fecal material, into the absorbentcore 38. In various embodiments, the exudate management layer 40 can beconfigured to have a first component 42 at least partially defining afirst opening 56 and a second opening 58. In various embodiments, theexudate management layer 40 can be configured to have a first component42 at least partially defining a first opening 56 and a second component70 connected to the first component 42 via a primary fold 72 and atleast partially defining a second opening 58.

Each of the first opening 56 and the second opening 58 can be anysuitable shape, such as, but not limited to, ovular, circular,rectangular, square, elliptical, hourglass, triangular, etc. In variousembodiments, the first opening 56 and the second opening 58 can have thesame shape and different size. In various embodiments, the first opening56 and the second opening 58 can have the shame shape and size. Invarious embodiments, the first opening 56 and the second opening 58 canhave different shapes but the same size. In various embodiments, theshape of the first opening 56 and/or the second opening 58 can include ashape of a physical object, such as, for example, the outer shape of aleaf, an animal, a star, a heart, a tear drop, a moon, or an abstractconfiguration. In various embodiments, the first opening 56 and/or thesecond opening 58 can be elongate and can be oriented in thelongitudinal direction (X) of the absorbent article 10. The firstopening 56 can form a cup or well-like structure for holding bodyexudates, such as urine, and preventing its leakage away from a regionof the absorbent article 10 and towards the edges of the absorbentarticle 10. The second opening 58 can also form a cup or well-likestructure for holding body exudates, such as fecal material, andpreventing its leakage away from a region of the absorbent articletowards the edges of the absorbent article 10.

The first opening 56 and the second opening 58 can be located at variouspositions along the longitudinal and transverse directions of theabsorbent article 10 depending upon the primary location of theirrespective desired body exudate intake within the absorbent article 10.This variability in positioning allows the first opening 56 and thesecond opening 58 to each be positioned below the main point of desiredbody exudate discharge so that each of the first opening 56 and thesecond opening 58 can act as the primary body exudate receiving areasfor the absorbent article 10. The first opening 56 can be positionedwithin the absorbent article 10 to be the primary receiving area forurine and the second opening 58 can be positioned to be the primaryreceiving area for fecal material. The absorbent article 10 can have alongitudinal centerline 18 and a transverse centerline 80. It should beunderstood that the longitudinal centerline 18 is disposed at a distancethat is equidistant from the longitudinal direction side edges 24 andruns the length of the absorbent article 10 in the longitudinaldirection (X), while the transverse centerline 80 is disposed at alocation that is equidistant from the first transverse direction endedge 20 and the second transverse direction end edge 22 and runs alongthe width of the absorbent article 10 in the transverse direction (Y).

In various embodiments, each of the first opening 56 and second opening58 can be positioned to be symmetrical about the longitudinal centerline18. In various embodiments, only one of the first opening 56 or thesecond opening 58 is symmetrical about the longitudinal centerline 18.In various embodiments, neither the first opening 56 nor the secondopening 58 is symmetrical about the longitudinal centerline 18. Invarious embodiments, the first opening 56 can be positioned to crossover the transverse centerline 80 of the absorbent article and thesecond opening 58 can be positioned between the transverse centerline 80and the second transverse direction end edge 22. In various embodiments,the first opening 56 can be positioned between the transverse centerline80 and the first transverse direction end edge 20 of the absorbentarticle 10 and the second opening 58 can be positioned to cross over thetransverse centerline 80. In various embodiments, the first opening 56can be positioned between the transverse centerline 80 and the firsttransverse direction end edge 20 of the absorbent article 10 and thesecond opening 58 can be positioned between the transverse centerline 80and the second transverse direction end edge 22 of the absorbent article10.

In various embodiments, at least one of the first opening 56 and/or thesecond opening 58 can be symmetrical about the longitudinal centerline18 and one of the first opening 56 or the second opening 58 can bepositioned to cross over the transverse centerline 80. In variousembodiments, each of the first opening 56 and the second opening 58 canbe symmetrical about the longitudinal centerline 18 and one of the firstopening 56 or the second opening 58 can be positioned to cross over thetransverse centerline 80. In various embodiments, each of the firstopening 56 and second opening 58 can be symmetrical about thelongitudinal centerline 18 and the first opening 56 can be positionedbetween the transverse centerline 80 and the first transverse directionend edge 20 and the second opening 58 can be positioned between thetransverse centerline 80 and the second transverse direction end edge22. In various embodiments, neither the first opening 56 nor the secondopening 58 is symmetrical about the longitudinal centerline 18 and oneof the first opening 56 or second opening 58 is positioned to cross overthe transverse centerline 80. In various embodiments, neither the firstopening 56 nor the second opening 58 is symmetrical about thelongitudinal centerline 18 and neither the first opening 56 nor thesecond opening 58 crosses over the transverse centerline 80.

Each of the first opening 56 and the second opening 58 in the exudatemanagement layer 40 can have a longitudinal length from about 15, 20,30, or 50 mm to about 60, 75, 100, or 150 mm and can have a transversewidth from about 10, 15, 20, or 30 mm to about 40, 60, 80, 100, 110,120, or 130 mm. Each of the first opening 56 and the second opening 58in the exudate management layer 40 can have a longitudinal length thatis from about 15, 20, or 25% to about 70, 75, or 80% of the overalllongitudinal length of the exudate management layer 40 in thelongitudinal direction (X). Each of the first opening 56 and the secondopening 58 in the exudate management layer 40 can have a transversewidth that can be from about 20, 25, or 30% to about 70, 75, or 80% ofthe overall width of the exudate management layer 40 in the transversedirection (Y). The first opening 56 can be sized as deemed suitable forthe receipt and isolation of urine and the second opening 58 can besized as deemed suitable for the receipt and isolation of fecal materialwithin the absorbent article 10.

In various embodiments, at least one of the first opening 56 and/or thesecond opening 58 can be associated with a barrier component via abarrier component fold. In various embodiments, for example, an exudatemanagement layer 40 can have a first opening 56 and a second opening 58and the first opening 56 can be associated with a first barriercomponent 64 via a first barrier component fold 66. In variousembodiments, an exudate management layer 40 can have a first opening 56and a second opening 58 and the second opening 58 can be associated witha second barrier component 74 via a second barrier component fold 76. Invarious embodiments, an exudate management layer 40 can have a firstopening 56 associated with a first barrier component 64 via a firstbarrier component fold 66 and a second opening 58 associated with asecond barrier component 74 via a second barrier component fold 76.

The barrier components, 64 and/or 74, can be in an at least partiallyoverlapping configuration with a portion of the exudate management layer40. In various embodiments, an at least partially overlappingconfiguration between a barrier component, 64 and/or 74, and a portionof the exudate management layer 40 can result in the barrier component,64 and/or 74, at least partially overlapping a portion of the exudatemanagement layer 40 such that the barrier component, 64 and 74, can bein contact with a portion of the body facing surface of the exudatemanagement layer 40. The portion of the barrier components, 64 and/or74, in contact with the portion of the body facing surface of theexudate management layer 40 can be bonded to each other such as, forexample, by adhesive bonding, thermal bonding, ultrasonic bonding, etc.In various embodiments, an at least partially overlapping configurationbetween a barrier component, 64 and/or 74, can result in the barriercomponent, 64 and/or 74, at least underlapping a portion of the exudatemanagement layer 40 such that the barrier component, 64 and/or 74, canbe in contact with a portion of the garment facing surface of theexudate management layer 40. The portion of the barrier component, 64and/or 74, in contact with the portion of the garment facing surface ofthe exudate management layer 40 can be bonded to each other such as, forexample, by adhesive bonding, thermal bonding, ultrasonic bonding, etc.

The barrier components, 64 and/or 74, can be formed from the same basesheet of material forming the exudate management layer 40 and areconnected to their respective opening, 56 and/or 58, via theirrespective barrier component folds, 66 and/or 76, in the materialforming the exudate management layer 40. Each of the barrier components,64 and/or 74, can extend from their respective barrier component folds,66 and/or 76, in the longitudinal direction (X) of the absorbent article10 in a direction towards the posterior region 14 of the absorbentarticle 10. The barrier components, 64 and/or 74, can help shape theabsorbent article 10, create a close-to-body fit, and absorb fluid froma wearer's buttock's region. The barrier components, 64 and/or 74, canalso reduce and/or prevent migration of one form of body exudate fromone region of the absorbent article 10 to another region of theabsorbent article 10. For example, a first barrier component 64extending from a first opening 56 in the longitudinal direction (X) andtowards the posterior region 14 of the absorbent article 10 can reduceand/or prevent fecal material migration from the posterior region 14 ofthe absorbent article 10 towards the anterior region 12 of the absorbentarticle 10. Such reduction and/or prevention of fecal material migrationwithin the absorbent article 10 can reduce the amount of fecal materialthat may come into contact with the genital region of the wearer of theabsorbent article 10.

In various embodiments, such as, for example, illustrated in FIG. 7A,the exudate management layer 40 can have a first component 42 defining afirst opening 56 and a second opening 58 and further having a barriercomponent 64 associated with the first opening 56 and extending in alongitudinal direction (X) towards the posterior region 14 of theabsorbent article 10. In such embodiments, the barrier component 64 canbe in an at least partially overlapping configuration with a portion ofthe first component 42. In such embodiments, the barrier component 64can also be in an at least partially overlapping configuration with thesecond opening 58. While the barrier component 64 is illustrated asextending in an at least partially overlapping configuration with thesecond opening 58, it is to be understood that the barrier component 64need not extend in an at least partially overlapping configuration withthe second opening 58. In various embodiments, such as, for example,illustrated in FIG. 7B, the exudate management layer 40 can have a firstcomponent 42 defining a first opening 56 and a second opening 58 andfurther having a barrier component 74 associated with the second opening58 and extending in a longitudinal direction (X) towards a posteriorregion 14 of the absorbent article 10. In such embodiments, the barriercomponent 74 can be in an at least partially overlapping configurationwith the first component 42. While the barrier component 74 isillustrated as not extending at least to the second transverse directionend edge 46, it is to be understood that such an extension is possible.In various embodiments, such as, for example, illustrated in FIG. 7C, anexudate management layer 42 can define a first opening 56 and a secondopening 58 and further have a first barrier component 64 associated withthe first opening 56 and a second barrier component 74 associated withthe second opening 58 wherein each barrier component, 64 and 74, extendin the longitudinal direction (X) of the absorbent article 10 toward theposterior region 14 of the absorbent article. In such embodiments, thefirst barrier component 64 is in an at least partially overlappingconfiguration with the first component 42 and with the second opening58. In such embodiments, the second barrier component 74 is in an atleast partially overlapping configuration with the first component 42.It is to be understood that at least one, and potentially both, of thefirst barrier component 64 and the second barrier component 74 can havea shorter longitudinal length and the first barrier component 64 neednot be in an at least partially overlapping configuration with thesecond opening 58 and the second barrier component 74 need not extendbeyond, or to, the second transverse direction end edge 46 of theexudate management layer 40.

When present in the absorbent article 10, the first barrier component 64and/or the second barrier component 74 can each have a first transversedirection end edge, 82 and 88, respectively, which is coextensive withthe barrier component fold, 66 and 76, respectively, a second transversedirection end edge, 84 and 90, respectively, and an opposing pair oflongitudinal direction side edges, 86 and 92, respectively, extendingbetween and connecting the transverse direction end edges, 82 and 84 and88 and 90, respectively. The barrier components, 64 and/or 74, cangenerally have any shape and/or size desired. The barrier components, 64and/or 74, can be created by cutting, punching, or otherwise separatingthe material forming the barrier components, 64 and/or 74, from thematerial forming the exudate management layer 40. Such cutting,punching, or otherwise separating of the barrier components, 64 and/or74, from the exudate management layer 40 will result in a first openingperimeter 60 which at least partially defines a first opening 64 and/ora second opening perimeter 62 which at least partially defines a secondopening 58.

The barrier components, 56 and/or 58, can positioned into an at leastpartially overlapping configuration with a portion of the exudatemanagement layer 40 by incorporating a barrier component fold, 64 and/or74, respectively, into the material forming the exudate management layer40. The barrier components, 64 and/or 74, are not fully separated fromthe exudate management layer 40 and remain attached to the exudatemanagement layer 40 via the barrier component folds, 64 and 74,respectively. In various embodiments, as the formation of the barriercomponents, 64 and/or 74, results in the formation of the openings, 56and/or 58, respectively, the barrier components, 64 and/or 74, can havea shape and size which can be considered a mate of and can becomplementary to the shape and size of the openings, 56 and/or 58,respectively. In various embodiments, the barrier components, 64 and/or74, therefore, when not in an at least partially overlappingconfiguration with the exudate management layer 40, can fit entirelywithin the openings, 56 and/or 58, respectively, of the exudatemanagement layer 40 and the edges, 84, 86, and 88 of the first barriercomponent 64 and/or 88, 90, and 92 of the second barrier component 74,can be adjacent to the perimeters, 60 and/or 62, respectively, of theexudate management layer 40. In various embodiments, the barriercomponents, 64 and/or 74, can be smaller in dimension than the openings,56 and/or 58, respectively, such as, for example, if the barriercomponent, 64 and/or 74, is further reduced in size dimension. In suchembodiments, the barrier components, 64 and/or 74, can fit entirelywithin the opening, 56 and/or 58, respectively, of the exudatemanagement layer 40, but the edges, 84, 86, and 88 of the first barriercomponent 64 and/or 88, 90, and 92 of the second barrier component 74,may not be adjacent to the perimeters, 60 and/or 62, respectively, ofthe exudate management layer 40. In various embodiments, a portion ofthe barrier components, 64 and/or 74, may be removed from the barriercomponents, 64 and/or 74, as part of the cutting or punching to form thebarrier components, 64 and/or 74, such that the second components, 64and/or 74, are not perfect mates or are not exactly complementary to theshape and size of the openings, 56 and/or 58, respectively.

The barrier components, 64 and/or 74, can have a longitudinal lengthfrom about 15, 20, 30, or 50 mm to about 60, 75, 100, or 150 mm and canhave a transverse width from about 10, 15, 20, or 30 mm to about 40, 60,80, 100, 110, 120, or 130 mm. In various embodiments, the barriercomponents, 64 and/or 74, can have a longitudinal direction length thatcan be from about 15, 20, 25, 30, 35, or 40% to about 50, 55, 60, 65,70, 75, 80, 85, or 90% of the longitudinal length of the exudatemanagement layer 40. In various embodiments, the barrier components, 64and/or 74, can have a transverse width that can be from about 15, 20,25, 30, 35, or 40% to about 50, 55, 60, 65, 70, 75, 80, 85, or 90% ofthe transverse width of the exudate management layer 40. The barriercomponent folds, 72 and/or 74, can provide a height dimension to theexudate management layer 40 and the height dimension in the depthdirection (Z) can be from about 0.5, 0.75, 1, 1.5, 2, 3, 3.5, 4, 4.5, 5,5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, or 10 mm to about 10.5, 11, 11.5,12, 12.5, 13, 13.5, 14, 14.5, 15, 15.5, 16, 16.5, 17, 17.5, 18, 18.5,19, 19.5, or 20 mm.

In various embodiments, a barrier component, 64 and/or 74, can have asecondary fold. The secondary fold can be a fold within the barriercomponent, 64 or 74, respectively, and can bring a first portion of thebarrier component, 64 or 74, respectively, into contact with a secondportion of the barrier component, 64 or 74, respectively. In variousembodiments, the first portion can be in an overlapping configurationwith the second portion. In various embodiments, the first portion canbe in an underlapping configuration with the second portion. In variousembodiments, the barrier component, 64 and/or 74, can have a singlesecondary fold. In various embodiments, the barrier component, 64 and/or74, can have a plurality of secondary folds.

FIGS. 3 and 4 provide an exemplary illustration of an absorbent article10, having an exudate management layer 40 in fluid communication withthe topsheet layer 30 of the absorbent article 10. In the embodimentillustrated in FIGS. 3 and 4 , the exudate management layer 40 ispositioned on the body facing surface 32 of the topsheet layer 30. Theexudate management layer 40 has a first component 42 defining a firstopening 56 and a second opening 58. Each of the first opening 56 andsecond opening 58 are positioned to be symmetrical about thelongitudinal centerline 18, but not symmetrical about the transversecenterline 80. The first opening 56 is positioned between the transversecenterline 80 and the first transverse direction end edge 20 of theabsorbent article 10 and the second opening 58 is positioned between thetransverse centerline 80 and the second transverse direction end edge 22of the absorbent article 10. The first opening 56 is associated with afirst barrier component 64 via a first barrier component fold 66 and thebarrier component 64 is in an at least partially overlappingconfiguration with the exudate management layer 40 such that the barriercomponent 64 is in contact with a portion of the body facing surface ofthe exudate management layer 40. The first opening 56 is general ovularin shape and the second opening 58 is generally rectangular in shape.

FIGS. 5 and 6 provide an exemplary illustration of an absorbent article10, having an exudate management layer 40 in fluid communication withthe topsheet layer 30 of the absorbent article 10. In the embodimentillustrated in FIGS. 5 and 6 , the exudate management layer 40 ispositioned between the topsheet layer 30 and the absorbent core 38. Theexudate management layer 40 has a first component 42 defining a firstopening 56 and a second opening 58. Each of the first opening 56 andsecond opening 58 are positioned to be symmetrical about thelongitudinal centerline 18, but not symmetrical about the transversecenterline 80. The first opening 56 is positioned between the transversecenterline 80 and the first transverse direction end edge 20 of theabsorbent article 10 and the second opening 58 is positioned between thetransverse centerline 80 and the second transverse direction end edge 22of the absorbent article 10. The first opening 56 is associated with afirst barrier component 64 via a first barrier component fold 66 and thebarrier component 64 is in an at least partially overlappingconfiguration with the exudate management layer 40 such that the barriercomponent 64 is in contact with a portion of the body facing surface ofthe exudate management layer 40. The first opening 56 is general ovularin shape and the second opening 58 is generally rectangular in shape.

In various embodiments, such as, for example, illustrated in theexemplary embodiments of FIGS. 7D and 7E, an opening, 56 and/or 58, canbe at least partially defined by a perimeter, 60 and 62, respectively,and at least partially by a barrier component, 64 and 74, respectivelyconnected to the opening, 56 and 58, respectively via a barriercomponent fold, 72 and 76, respectively. In various embodiments, anopening, 56 and/or 58, can have a supplemental barrier componentassociated with the opening, 56 and/or 58, via a supplemental componentfold. In various embodiments, an opening, 56 and/or 58, can have atleast 1, 2, or 3 supplemental barrier components associated with theopening, 56 and/or 58. Referring to FIG. 7D, FIG. 7D provides anexemplary illustration of an exudate management layer 40 having a firstcomponent 42, a first opening 56 and a second opening 58. A barriercomponent 64 is connected to the first opening 56 via a barriercomponent fold 66 and a supplement barrier component 94 is connected tothe first opening 56 via a supplement barrier component fold 96. Theopening 56 is defined by the first component 42, the barrier componentfold 66, and the supplemental barrier component fold 96. Thesupplemental barrier component 94 can extend from the supplement barriercomponent fold 96 in the longitudinal direction (X) of the absorbentarticle 10 in a direction towards the anterior region 12 of theabsorbent article 10. Referring to FIG. 7E, FIG. 7E provides anexemplary illustration of an exudate management layer 40 having a firstcomponent 42, a first opening 56, and a second opening 58. A barriercomponent 74 is connected to the second opening 58 via barrier componentfold 76 and a supplemental barrier component 130 can be connected to thesecond opening 58 via supplemental barrier component fold 132. Thesecond opening 58 is defined by the first component 42, the barriercomponent fold 76, and the supplemental barrier component fold 132. Eachof the barrier component 74 and the supplement barrier component 130 canextend away from the second opening 58 in the transverse direction (Y)of the absorbent article 10.

In various embodiments, such as, for example, illustrated in FIG. 7F,the exudate management layer 40 can have at least two second openings 58for the capture and retention of fecal material. In various embodiments,the exudate management layer 40 can have at least 1, 2, 3, 4, or 5second openings 58. Each of the second openings 58 can have any shape asdeemed suitable such as, for example, described herein. Each of thesecond openings 58 can be at least partially bounded by a perimeter 62and at least partially bounded by a barrier component fold 76 of theirrespective barrier component 74. The plurality of second openings 58 canbe arranged in the exudate management layer 40 in any manner deemedsuitable. In various embodiments, at least one of the second openings 58can be symmetrical about the longitudinal centerline 18 of the absorbentarticle 10. In various embodiments, none of the plurality of secondopenings 58 can be symmetrical about the longitudinal centerline 18 ofthe absorbent article 10. In various embodiments, one of the pluralityof second openings 58 can be positioned such that it can cross over thetransverse centerline 80 of the absorbent article 10. In variousembodiments, each of the plurality of second openings 58 can bepositioned between the transverse centerline 80 and the secondtransverse direction end edge 22 of the absorbent article 10.

In various embodiments, the exudate management layer 40 can beconfigured to have a first component 42 at least partially defining afirst opening 56 and a second component 70 at least partially defining asecond opening 58. The second component 70 is in an at least partiallyoverlapping configuration with the first component 42. The secondcomponent 70 is formed from the same base sheet of material forming thefirst component 42 of the exudate management layer 40 and is connectedto the first component 42 via a primary fold 72 in the material formingthe exudate management layer 40. In various embodiments, the secondcomponent 70 can extend from the primary fold 72 in the longitudinaldirection (X) of the absorbent article 10 towards the posterior region14 of the absorbent article 10.

The second component 70 can be formed by cutting, punching, or otherwiseseparating the material forming the second component 70 from thematerial forming the first component 42. Following the cutting,punching, or otherwise separating of the material, a primary fold 70 canbe incorporated into the exudate management layer 40 to reposition thematerial forming the second component 70 into an at least partiallyoverlapping configuration with a portion of the material forming thefirst component 42. In various embodiments, the second component 70 canat least partially overlap the first component 42. In variousembodiments, the second component 70 can at least partially underlap thefirst component 42.

Such cutting, punching, or otherwise separating the second component 70from the material forming the first component 42 will result in theprovision of the shape and size dimension of the first component 42, aswell as the first transverse direction end edge 44, the secondtransverse direction end edge 46, and the longitudinal direction sideedges 48 extending between and connecting the first transverse directionend edge 44 and the second transverse direction end edge 46. Suchcutting, punching, or otherwise separating of the second component 70from the first component 42 will result in the perimeter 62 which atleast partially defines the second opening 58 in the second component70. The second opening 58 can also be at least partially defined by thesecond transverse direction end edge 46 of the first component 42.

The exudate management layer 40 having a first component 42 and a secondcomponent 70 can generally have any shape and size as deemed suitable.In various embodiments, the exudate management layer 40 having a firstcomponent 42 and a second component 70 can have an overall shape suchas, for example, a rectangular shape, a curved rectangular shape, anoval shape, an elliptical shape, a circular shape, an hourglass shape, atriangular shape, a square shape, or a curved square shape. In variousembodiments, each of the first component 42 and second component 70 canhave a shape such as, a rectangular shape, a curved rectangular shape,an oval shape, an elliptical shape, a circular shape, an hourglassshape, a triangular shape, a square shape, or a curved square shape. Invarious embodiments, each of the first component 42 and the secondcomponent 70 have the same shape. In various embodiments, each of thefirst component 42 and the second component have different shapes.

In various embodiments, the second component 70 can have a longitudinaldirection length which can be less than the overall length of theabsorbent article 10. For example, the second component 70 can have alongitudinal length between about 20, 30, 40, 50, 60, 80, 100, 150, 175,or 200 mm to about 220, 240, 260, 280, 300, 320, 340, 360, 380, 400,420, 440, 460, 480, or 500 mm. In various embodiments, the secondcomponent 70 can have a longitudinal direction length that is from about15, 20, 25, 30, 35, or 40% to about 50, 55, 60, 65, 70, 75, 80, 85, or90% of the longitudinal length of the absorbent article 10. In variousembodiments, the second component 70 can have a transverse width whichcan be equal to or less than the overall width of the absorbent article10. For example, the second component 70 can have a transverse widthbetween about 10, 15, 20, 30, 40, 50, 60, 70, or 80 mm to about 90, 100,110, 120, 130, 140, 150, 160, or 170 mm. In various embodiments, thesecond component 70 can have a transverse width that is from about 15,20, 25, 30, 35, of 40% to about 50, 55, 60, 65, 70, 75, 80, 85, or 90%of the transverse width of the absorbent article 10. In variousembodiments, the transverse width of the second component 70 can beuniform in the longitudinal direction of the second component 70. Invarious embodiments, the transverse width of the second component 70 canvary along the longitudinal direction of the second component 70. Thesecond component 70 can have a height in the depth direction (Z) fromthe body facing surface of the second component 70 to the garment facingsurface of the second component 70 from about 0.5, 0.75, 1, 1.5, 2, or3.5 mm to about 3, 3.5, 4, 4.5, 5, 6, or 10 mm.

FIGS. 8 and 9 provide an exemplary illustration of an absorbent article10, having an exudate management layer 40 in fluid communication withthe topsheet layer 30 of the absorbent article 10. In the embodimentillustrated in FIGS. 8 and 9 , the exudate management layer 40 ispositioned on the body facing surface 32 of the topsheet layer 30. Theexudate management layer 40 has a first component 42 defining a firstopening 56 and a second component 70 defining a second opening 58. Thesecond component is connected to the first component via a primary fold72. Each of the first opening 56 and second opening 58 are positioned tobe symmetrical about the longitudinal centerline 18, but not symmetricalabout the transverse centerline 80. The first opening 56 is positionedbetween the transverse centerline 80 and the first transverse directionend edge 20 of the absorbent article 10 and the second opening 58 ispositioned between the transverse centerline 80 and the secondtransverse direction end edge 22 of the absorbent article 10. The firstopening 56 is associated with a first barrier component 64 via a firstbarrier component fold 66 and the barrier component 64 is in an at leastpartially overlapping configuration with the exudate management layer 40such that the barrier component 64 is in contact with a portion of thebody facing surface of the exudate management layer 40. The firstopening 56 is general ovular in shape and the second opening 58 isgenerally rectangular in shape.

FIGS. 10 and 11 provide an exemplary illustration of an absorbentarticle 10, having an exudate management layer 40 in fluid communicationwith the topsheet layer 30 of the absorbent article 10. In theembodiment illustrated in FIGS. 5 and 6 , the exudate management layer40 is positioned between the topsheet layer 30 and the absorbent core38. The exudate management layer 40 has a first component 42 defining afirst opening 56 and a second component 70 defining a second opening 58.The second component 70 is connected to the first component 42 via aprimary fold 72. Each of the first opening 56 and second opening 58 arepositioned to be symmetrical about the longitudinal centerline 18, butnot symmetrical about the transverse centerline 80. The first opening 56is positioned between the transverse centerline 80 and the firsttransverse direction end edge 20 of the absorbent article 10 and thesecond opening 58 is positioned between the transverse centerline 80 andthe second transverse direction end edge 22 of the absorbent article 10.The first opening 56 is associated with a first barrier component 64 viaa first barrier component fold 66 and the barrier component 64 is in anat least partially overlapping configuration with the exudate managementlayer 40 such that the barrier component 64 is in contact with a portionof the body facing surface of the exudate management layer 40. The firstopening 56 is general ovular in shape and the second opening 58 isgenerally rectangular in shape.

FIGS. 12A-12C provide additional exemplary embodiments of an exudatemanagement layer 40 having a first component 42 defining a first opening56 and a second component 70 defining a second opening 58 wherein thesecond component 70 is in an at least partially overlappingconfiguration with the first component 42 and wherein the secondcomponent 70 is connected to the first component 42 via a primary fold72. FIG. 12A provides an exemplary illustration of an exemplaryembodiment of an exudate management layer 40 which has a first component42 defining a first opening 56 and a second component 70 defining asecond opening 58. The second component 70 is in an at least partiallyoverlapping configuration with the first component 42. In the embodimentillustrated in FIG. 12A, the second component 70 is folded at a primaryfold 72 and folded so that the second component 72 at least partiallyoverlaps the first component 42. The exudate management layer 40 has agenerally rectangular shape and each of the first component 42 and thesecond component 70 have a generally rectangular shape. The firstopening 56 is at least partially defined by perimeter 60 and at leastpartially defined by barrier component fold 66 which connects the firstcomponent 42 to a first barrier 64. The first barrier 64 can extend inthe longitudinal direction (X) and can be in an at least partiallyoverlapping configuration with the first component 42 and extend overthe second opening 58. The first opening 56 and the barrier component 64are each generally ovular in shape and the second opening 58 isgenerally rectangular in shape. The barrier component fold 66 is notaligned with the primary fold 72 in the exemplary embodiment illustratedin FIG. 12A. FIG. 12B provides an exemplary illustration of an exemplaryembodiment of an exudate management layer 40 which has a first component42 defining a first opening 56 and a second component 70 defining asecond opening 58. The second component 70 is in an at least partiallyoverlapping configuration with the first component 42. In the embodimentillustrated in FIG. 12B, the second component 70 is folded at a primaryfold 72 and folded so that the second component 72 at least partiallyoverlaps the first component 42. The exudate management layer 40 has agenerally rectangular shape and each of the first component 42 and thesecond component 70 have a generally rectangular shape. The firstopening 56 is at least partially defined by perimeter 60 and at leastpartially defined by barrier component fold 66 which connects the firstcomponent 42 to a first barrier 64. The first barrier 64 can extend inthe longitudinal direction (X) and can be in an at least partiallyoverlapping configuration with the first component 42 and extend overthe second opening 58. The first opening 56 and the barrier component 64are each generally ovular in shape and the second opening 58 isgenerally rectangular in shape. The barrier component fold 66 is alignedwith the primary fold 72 in the exemplary embodiment illustrated in FIG.12B. FIG. 12C provides an exemplary illustration of an exemplaryembodiment of an exudate management layer 40 which has a first component42 defining a first opening 56 and a second component 70 defining asecond opening 58. The second component 70 is in an at least partiallyoverlapping configuration with the first component 42. In the embodimentillustrated in FIG. 12C, the second component 70 is folded at a primaryfold 72 and folded so that the second component 72 at least partiallyoverlaps the first component 42. The exudate management layer 40 has agenerally hourglass shape and each of the first component 42 and thesecond component 70 have a generally triangular shape. The first opening56 is at least partially defined by perimeter 60 and at least partiallydefined by barrier component fold 66 which connects the first component42 to a first barrier 64. The first barrier 64 can extend in thelongitudinal direction (X) and can be in an at least partiallyoverlapping configuration with the first component 42 and extend overthe second opening 58. The first opening 56 and the barrier component 64are each generally ovular in shape and the second opening 58 isgenerally triangular in shape. The barrier component fold 66 is alignedwith the primary fold 72 in the exemplary embodiment illustrated in FIG.12C.

Referring to FIG. 13 , in various embodiments, the barrier component 74connected to the second opening 58 of the exudate management layer 40can have at least one opening 140 which can be any suitable shape, suchas, but not limited to, ovular, circular, rectangular, square,elliptical, hourglass, triangle, etc. In various embodiments, the shapeof the opening 140 can include a shape of a physical object, such as,for example, the outer shape of a leaf, an animal, a star, a heart, atear drop, a moon, or an abstract configuration. In various embodiments,the opening 140 can be elongate and can be oriented in the longitudinaldirection (X) of the absorbent article 10. The opening 140 can bebounded by a perimeter 142 which can form an inner border or inner edgeof the barrier component 74. The opening 140 in the barrier component 74can pass through the barrier component 74 from the body facing surfaceof the barrier component 74 to the garment facing surface of the barriercomponent 74. In the event of body exudate coming into the location ofthe opening 140 in the barrier component, the opening 74 can form a cupor well-like structure for holding body exudate and preventing itsleakage away from a region of the absorbent article 10 and towards theedges of the absorbent article 10. The opening 140 can be located atvarious positions of the barrier component 74. In various embodiments,the barrier component 74 can have more than one opening 140 and theplurality of openings 140 can be arranged in the barrier component 74 inany manner deemed suitable. In various embodiments, the opening 140 canbe formed by cutting, punching, or otherwise separating a first portionof the material forming the barrier component 74 from a second portionof material forming the barrier component 74. The second portion ofmaterial forming the barrier component 74 is that portion of materialwhich remains as the barrier component 74 of the exudate managementlayer 40 and is connected to the second opening via the barrier fold 76.In various embodiments, the first portion of the material which has beencut, punched, or otherwise separated from the second portion of materialforming the barrier component 74 can be discarded. In variousembodiments, the first portion of the material which has been cut,punched, or otherwise separated from the second portion of materialforming the barrier component 74 can be bonded to the absorbent core 38and can form projection(s) 144 extending upward, in the depth direction(Z) from the body facing surface of the absorbent core 38. The materialforming the projection(s) 144 can be bonded to the absorbent core 38prior to or after the cutting, punching, or otherwise separating thefirst portion of material forming the barrier component 74 from thesecond portion of material forming the barrier component 74.

Referring to FIG. 14 , in various embodiments, the absorbent core 38 canhave at least one opening 150 which can be any suitable shape, such as,but not limited to, ovular, circular, rectangular, square, elliptical,hourglass, triangle, etc. In various embodiments, the shape of theopening 150 can include a shape of a physical object, such as, forexample, the outer shape of a leaf, an animal, a star, a heart, a teardrop, a moon, or an abstract configuration. In various embodiments, theopening 150 can be elongate and can be oriented in the longitudinaldirection (X) of the absorbent article 10. The opening 150 can bebounded by a perimeter 152 which can form an inner border or inner edgeof the absorbent core 38. The opening 150 in the absorbent core 38passes through the absorbent core 38 from the body facing surface of theabsorbent core 38 to the garment facing surface of the absorbent core38. In the event of body exudate coming into the location of the opening150 in the absorbent core 38, the opening 150 can form a cup orwell-like structure for holding the body exudate and preventing itsleakage away from a region of the absorbent article 10 and towards theedges of the absorbent article 10. The opening 150 can be located atvarious positions of the absorbent core 38 and within the region of theabsorbent core 38 visible through the opening 56 of the exudatemanagement layer 40. In various embodiments, the absorbent core 38 canhave more than one opening 150 and the plurality of openings 150 can bearranged in the absorbent core 38 in any manner deemed suitable. Theopening 150 in the absorbent core 38 can be formed by cutting, punching,or otherwise separating a first portion of material forming theabsorbent core 38 from a second portion of material forming theabsorbent core 38. The second portion of material forming the absorbentcore 38 is that portion of material which remains as the absorbent core38 of the absorbent article 10. In various embodiments, the firstportion of the material which has been cut, punched, or otherwiseseparated from the second portion of material forming the absorbent core38 can be discarded. In various embodiments, the first portion of thematerial which has been cut, punched, or otherwise separated from thesecond portion of material forming the absorbent core 38 can be bondedto the barrier component 64 of the exudate management layer 40 and canform projection(s) 154 extending upward, in the depth direction (Z) fromthe body facing surface of the barrier component 74. The materialforming the projection(s) 154 can be bonded to the barrier component 74prior to or after the cutting, punching, or otherwise separating of thebarrier component 74 from the first component 42 of the exudatemanagement layer 40.

Containment Flaps:

In various embodiments, the absorbent article can have containmentflaps. FIGS. 2-6 and 8-11 provide illustrations of exemplary embodimentsof an absorbent article 10 with containment flaps, 210 and 212. Invarious embodiments, containment flaps, 210 and 212, can be secured tothe topsheet layer 30 of the absorbent article 10 in a generallyparallel, spaced relation with each other laterally inward of thelongitudinal direction side edges 24 to provide a barrier against theflow of body exudates in the transverse direction (Y) of the absorbentarticle 10. In various embodiments, the containment flaps, 210 and 212,can extend longitudinally from the anterior region 12 of the absorbentarticle 10, through the central region 16 to the posterior region 14 ofthe absorbent article 10.

The containment flaps, 210 and 212, can be constructed of a fibrousmaterial which can be similar to the material forming the topsheet layer30. Other conventional material, such as polymer films, can also beemployed. Each containment flap, 210 and 212, can have a moveable distalend 214 which can include flap elastics 216. Suitable elastic materialsfor the flap elastics 216 can include sheets, strands or ribbons ofnatural rubber, synthetic rubber, or thermoplastic elastomericmaterials. In various embodiments, the flap elastics 216 can have twostrands of elastomeric material extending longitudinally along thedistal ends 214 of the containment flaps, 210 and 212, in generallyparallel, spaced relation with each other. The elastic strands can bewithin the containment flaps, 210 and 212, while in an elasticallycontractible condition such that contraction of the strands gathers andshortens the distal ends 214 of the containment flaps, 210 and 212. As aresult, the elastic strands can bias the distal ends 214 of eachcontainment flap, 210 and 212, toward a position spaced from theproximal end of the containment flaps, 210 and 212, so that thecontainment flaps, 210 and 212, can extend away from the topsheet layer30 in a generally upright orientation of the containment flaps, 210 and212, especially in the central region 16 of the absorbent article 10,when the absorbent article 10 is fitted on the wearer. The distal end214 of the containment flaps, 210 and 212, can be connected to the flapelastics 216 by partially doubling the containment flap, 210 and 212,material back upon itself by an amount which can be sufficient toenclose the flap elastics 216. It is to be understood, however, that thecontainment flaps, 210 and 212, can have any number of strands ofelastomeric material and may also be omitted from the absorbent article10 without departing from the scope of this disclosure.

In various embodiments, such as, for example, illustrated in FIGS. 3, 4,8, and 9 , the absorbent article 10 can have an exudate management layer40 positioned on the body facing surface 32 of the topsheet layer 30. Invarious embodiments, the exudate management layer 40 can be sized andpositioned such that the longitudinal direction side edges 48 of theexudate management layer 40 are located underneath the containmentflaps, 210 and 212, of the absorbent article 10. In such embodiments,when the containment flaps, 210 and 212, extend away from the topsheetlayer 30 in a generally upright orientation of the containment flaps,210 and 212, the exudate management layer 40 can be elevated away fromthe topsheet layer 30 and provide a close to body fit of the absorbentarticle 10 to the body of the wearer. In various embodiments, thetransverse direction end edges, 44 and 46, and the longitudinaldirection side edges 48 of the exudate management layer 40 can be bondedto the topsheet layer 30 so as to create a pocket for the body exudatewhen the exudate management layer 40 is elevated away from the topsheetlayer 30 as the containment flaps, 210 and 212, are in a generallyupright orientation during usage of the absorbent article 10.

Acquisition Layer:

In various embodiments, the absorbent article 10 can have an acquisitionlayer. The acquisition layer can help decelerate and diffuse surges orgushes of liquid body exudates penetrating the topsheet layer 30. Invarious embodiments, the exudate management layer 40 can be positionedon the body facing surface 32 of the topsheet layer 30 and theacquisition layer can be positioned between the topsheet layer 30 andthe absorbent core 38. In various embodiments, the acquisition layer canbe positioned on the body facing surface 32 of the topsheet layer 30 andthe exudate management layer 40 can be positioned on the body facingsurface of the acquisition layer. In various embodiments, an absorbentarticle 10 can have an exudate management layer 40 positioned betweenthe topsheet layer 30 and the absorbent core 38 with an acquisitionlayer positioned between the exudate management layer 40 and theabsorbent core 38.

The acquisition layer may have any longitudinal length dimension asdeemed suitable. In various embodiments, the longitudinal length of theacquisition layer can be the same as the longitudinal length of theabsorbent core 38. In various embodiments, the longitudinal length ofthe acquisition layer can be shorter than the longitudinal length of theabsorbent core 38. In such embodiments, the acquisition layer may bepositioned at any desired location along the longitudinal length of theabsorbent core 38.

In an embodiment, the acquisition layer can include natural fibers,synthetic fibers, superabsorbent material, woven material, nonwovenmaterial, wet-laid fibrous webs, a substantially unbounded airlaidfibrous web, an operatively bonded, stabilized-airlaid fibrous web, orthe like, as well as combinations thereof. In an embodiment, theacquisition layer can be formed from a material that is substantiallyhydrophobic, such as a nonwoven web composed of polypropylene,polyethylene, polyester, and the like, and combinations thereof. Invarious embodiments, the acquisition layer can include conjugate,biconstituent, and/or homopolymer fibers of staple or other lengths andmixtures of such fibers with other types of fibers. In variousembodiments, the acquisition layer can have fibers which can have adenier of greater than about 5. In various embodiments, the acquisitionlayer can have fibers which can have a denier of less than about 5.

In various embodiments, the acquisition layer can be a bonded carded webor an airlaid web. In various embodiments, the bonded carded web may be,for example, a powder bonded carded web, an infrared bonded carded web,or a through air bonded carded web.

In various embodiments, the basis weight of the acquisition layer can beat least about 10 or 20 gsm. In various embodiments, the basis weight ofthe acquisition layer can be from about 10, 20, 30, 40, 50 or 60 gsm toabout 65, 70, 75, 80, 85, 90, 100, 110, 120, or 130 gsm. In variousembodiments, the basis weight of the acquisition layer can be less thanabout 130, 120, 110, 100, 90, 85, 80, 75, 70, 65, 60 or 50 gsm.

Side Panels:

FIG. 21 provides an illustration of an exemplary embodiment of aperspective view of an absorbent article 10 such as a pant, such as, forexample, a training pant, youth pant, diaper pant, or an adultincontinence pant. In an embodiment in which the absorbent article 10can be a training pant, youth pant, diaper pant, or adult incontinencepant, the absorbent article 10 may have front side panels, 260 and 262,and rear side panels, 264 and 266. FIG. 21 provides a non-limitingillustration of an absorbent article 10 that can have side panels, suchas front side panels, 260 and 262, and rear side panels, 264 and 266.The front side panels 260 and 262 and the rear side panels 264 and 266of the absorbent article 10 can be bonded to the absorbent article 10 inthe respective anterior and posterior regions, 12 and 14, and can extendoutwardly beyond the longitudinal side edges 24 of the absorbent article10. In an example, the front side panels, 260 and 262, can be bonded tothe liquid impermeable layer 36 such as being bonded thereto byadhesive, by pressure bonding, by thermal bonding or by ultrasonicbonding. The back side panels, 264 and 266, may be secured to the liquidimpermeable layer 36 in substantially the same manner as the front sidepanels, 260 and 262. Alternatively, the front side panels, 260 and 262,and the back side panels, 264 and 266, may be formed integrally with theabsorbent article 10, such as by being formed integrally with the liquidimpermeable layer 36, the topsheet layer 30 or other layers of theabsorbent article 10.

For improved fit and appearance, the front side panels, 260 and 262, andthe back side panels, 264 and 266, can suitably have an average lengthmeasured parallel to the longitudinal centerline 18 of the absorbentarticle 10 that is about 20 percent or greater, and more suitably about25 percent or greater, of the overall length of the absorbent article10, also measured parallel to the longitudinal centerline 18. Forexample, absorbent articles 10 having an overall length of about 54centimeters, the front side panels, 260 and 262, and the back sidepanels, 264 and 266, suitably have an average length of about 10centimeters or greater, and more suitably have an average length ofabout 15 centimeters. Each of the front side panels, 260 and 262, andback side panels, 264 and 266, can be constructed of one or moreindividual, distinct pieces of material. For example, each front sidepanel, 260 and 262, and back side panel, 264 and 266, can include firstand second side panel portions (not shown) joined at a seam (not shown),with at least one of the portions including an elastomeric material.Alternatively, each individual front side panel, 260 and 262, and backside panel, 264 and 266, can be constructed of a single piece ofmaterial folded over upon itself along an intermediate fold line (notshown).

The front side panels, 260 and 262, and back side panels, 264 and 266,can each have an outer edge 270 spaced laterally from the engagementseam 272, a leg end edge 274 disposed toward the longitudinal center ofthe absorbent article 10, and a waist end edge 276 disposed toward alongitudinal end of the absorbent article 10. The leg end edge 274 andwaist end edge 276 can extend from the longitudinal side edges 24 of theabsorbent article 10 to the outer edges 270. The leg end edges 274 ofthe front side panels, 260 and 262, and back side panels, 264 and 266,can form part of the longitudinal side edges 24 of the absorbent article10. The leg end edges 274 of the illustrated absorbent article 10 can becurved and/or angled relative to the transverse centerline 80 to providea better fit around the wearer's legs. However, it is understood thatonly one of the leg end edges 274 can be curved or angled, such as theleg end edge 274 of the posterior region 14, or neither of the leg endedges 274 can be curved or angled, without departing from the scope ofthis disclosure. The waist end edges 276 can be parallel to thetransverse centerline 80. The waist end edges 276 of the front sidepanels, 260 and 262, can form part of the first transverse direction endedge 20 of the absorbent article 10, and the waist end edges 276 of theback side panels, 264 and 266, can form part of the second transversedirection end edge 22 of the absorbent article 10.

The front side panels, 260 and 262, and back side panels, 264 and 266,can include an elastic material capable of stretching laterally.Suitable elastic materials, as well as one described process forincorporating elastic front side panels, 260 and 262, and back sidepanels, 264 and 266, into an absorbent article 10 are described in thefollowing U.S. Pat. No. 4,940,464 issued Jul. 10, 1990 to Van Gompel etal., U.S. Pat. No. 5,224,405 issued Jul. 6, 1993 to Pohjola, U.S. Pat.No. 5,104,116 issued Apr. 14, 1992 to Pohjola, and U.S. Pat. No.5,046,272 issued Sep. 10, 1991 to Vogt et al.; all of which areincorporated herein by reference. As an example, suitable elasticmaterials include a stretch-thermal laminate (STL), a neck-bondedlaminate (NBL), a reversibly necked laminate, or a stretch-bondedlaminate (SBL) material. Methods of making such materials are well knownto those skilled in the art and described in U.S. Pat. No. 4,663,220issued May 5, 1987 to Wisneski et al., U.S. Pat. No. 5,226,992 issuedJul. 13, 1993 to Morman, and European Patent Application No. EP 0 217032 published on Apr. 8, 1987, in the names of Taylor et al., and PCTApplication WO 01/88245 in the name of Welch et al., all of which areincorporated herein by reference. Other suitable materials are describedin U.S. patent application Ser. No. 12/649,508 to Welch et al. and Ser.No. 12/023,447 to Lake et al., all of which are incorporated herein byreference. Alternatively, the front side panels, 260 and 262, and backside panels, 264 and 266, may include other woven or non-wovenmaterials, such as those described above as being suitable for theliquid impermeable layer 36.

Method to Determine Percent Open Area:

The percentage of open area can be determined by using the imageanalysis measurement method described herein. In this context, the openarea is considered the regions within a material where light transmittedfrom a light source passes directly thru those regions unhindered in thematerial of interest. Generally, the image analysis method determines anumeric value of percent open area for a material via specific imageanalysis measurement parameters such as area. The percent open areamethod is performed using conventional optical image analysis techniquesto detect open area regions in both land areas and projectionsseparately and then calculating their percentages in each. To separateland areas and projections for subsequent detection and measurement,incident lighting is used along with image processing steps. An imageanalysis system, controlled by an algorithm, performs detection, imageprocessing and measurement and also transmits data digitally to aspreadsheet database. The resulting measurement data are used todetermine the percent open area of materials possessing land areas andprojections.

The method for determining the percent open area in both land areas andprojections of a given material includes the step of acquiring twoseparate digital images of the material. An exemplary setup foracquiring the image is representatively illustrated in FIG. 22 .Specifically, a CCD video camera 300 (e.g., a Leica DFC 310 FX videocamera operated in gray scale mode and available from Leica Microsystemsof Heerbrugg, Switzerland) is mounted on a standard support 302 such asa Polaroid MP-4 Land Camera standard support or equivalent availablefrom Polaroid Resource Center in Cambridge, Miss. The standard support302 is attached to a macro-viewer 304 such as a KREONITE macro-vieweravailable from Dunning Photo Equipment, Inc., having an office in Bixby,Okla. An auto stage 308 is placed on the upper surface 306 of themacro-viewer 304. The auto stage 308 is used to automatically move theposition of a given material for viewing by the camera 300. A suitableauto stage is Model H112, available from Prior Scientific Inc., havingan office in Rockland, Mass.

The material possessing land areas and projections is placed on the autostage 308 under the optical axis of a 60 mm Nikon AF Micro Nikkor lens310 with an f-stop setting of 4. The Nikon lens 310 is attached to theLeica DFC 310 FX camera 300 using a c-mount adaptor. The distance D1from the front face 312 of the Nikon lens 310 to the material is 21 cm.The material is laid flat on the auto stage 308 and any wrinkles removedby gentle stretching and/or fastening it to the auto stage 308 surfaceusing transparent adhesive tape at its outer edges. The material isoriented so the machine-direction (MD) runs in the horizontal directionof the resulting image. The material surface is illuminated withincident fluorescent lighting provided by a 16 inch diameter, 40 watt,GE Circline fluorescent lamp 314. The lamp 314 is contained in a fixturethat is positioned so it is centered over the material and under thevideo camera above and is a distance D2 of 3 inches above the materialsurface. The illumination level of the lamp 314 is controlled with aVariable Auto-transformer, type 3PN1010, available from Staco EnergyProducts Co. having an office in Dayton, Ohio. Transmitted light is alsoprovided to the material from beneath the auto stage 308 by a bank offive 20 watt fluorescent lights 316 covered with a diffusing plate 318.The diffusing plate 318 is inset into, and forms a portion of, the uppersurface 306 of the macro-viewer 304. The diffusing plate 318 is overlaidwith a black mask 320 possessing a 3-inch by 3-inch opening 322. Theopening 322 is positioned so that it is centered under the optical axisof the Leica camera and lens system. The distance D3 from the opening322 to the surface of the auto stage 308 is approximately 17 cm. Theillumination level of the fluorescent light bank 316 is also controlledwith a separate Variable Auto-transformer.

The image analysis software platform used to perform the percent openarea measurements is a QWIN Pro (Version 3.5.1) available from LeicaMicrosystems, having an office in Heerbrugg, Switzerland. The system andimages are also calibrated using the QWIN software and a standard rulerwith metric markings at least as small as one millimeter. Thecalibration is performed in the horizontal dimension of the video cameraimage. Units of millimeters per pixel are used for the calibration.

The method for determining the percent open area of a given materialincludes the step of performing several area measurements from bothincident and transmitted light images. Specifically, an image analysisalgorithm is used to acquire and process images as well as performmeasurements using Quantimet User Interactive Programming System (QUIPS)language. The image analysis algorithm is reproduced below.

NAME = % Open Area − Land vs Projection Regions−1 PURPOSE = Measures %open area on ‘land’ and ‘projection’ regions via ‘sandwich’ lightingtechnique DEFINE VARIABLES & OPEN FILES Open File ( C:\Data\39291\% OpenArea\data.xls, channel #1 ) MFLDIMAGE = 2 TOTCOUNT = 0 TOTFIELDS = 0SAMPLE ID AND SET UP Configure ( Image Store 1392 x 1040, Grey Images81, Binaries 24 ) Enter Results Header File Results Header ( channel #1) File Line ( channel #1 ) Image Setup DC Twain [PAUSE] ( Camera 1,AutoExposure Off, Gain 0.00, ExposureTime 34.23 msec, Brightness 0, Lamp38.83 ) Measure frame ( x 31, y 61, Width 1330, Height 978 ) Image frame( x 0, y 0, Width 1392, Height 1040 ) -- Calvalue = 0.0231 mm/pxCALVALUE = 0.0231 Calibrate ( CALVALUE CALUNITS$ per pixel ) ClearAccepts For ( SAMPLE = 1 to 1, step 1 ) Clear Accepts File ( “FieldNo.”, channel #1, field width: 9, left justified ) File ( “Land Area”,channel #1, field width: 9, left justified ) File ( “Land Open Area”,channel #1, field width: 13, left justified ) File ( “%Open Land Area”,channel #1, field width: 15, left justified ) File ( “Proj. Area”,channel #1, field width: 9, left justified ) File ( “Proj. Open Area”,channel #1, field width: 13, left justified ) File ( “% Open Proj.Area”, channel #1, field width: 15, left justified ) File ( “Total %Open Area”, channel #1, field width: 14, left justified ) File Line (channel #1 ) Stage ( Define Origin ) Stage ( Scan Pattern, 5 x 1 fields,size 82500.000000 x 82500.000000 ) IMAGE ACQUISITION I - Projectionisolation For ( FIELD = 1 to 5, step 1 )  Display ( Image0 (on), frames(on,on), planes (off,off,off,off,off,off), lut 0, x 0, y 0, z 1,Reduction off)  PauseText ( “Ensure incident lighting is correct (WL =0.88 − 0.94) and acquire image.” )  Image Setup DC Twain [PAUSE] (Camera 1, AutoExposure Off, Gain 0.00, ExposureTime 34.23 msec,Brightness 0, Lamp 38.83 )  Acquire ( into Image0 ) DETECT - Projectionsonly PauseText ( “Ensure that threshold is set at least to the right ofthe left gray-level histogram peak which corresponds to the ‘land’region.” ) Detect [PAUSE] ( whiter than 127, from Image0 into Binary0delineated ) BINARY IMAGE PROCESSING Binary Amend (Close from Binary0 toBinary1, cycles 10, operator Disc, edge erode on) Binary Identify (FillHoles from Binary1 to Binary1 ) Binary Amend (Open from Binary1 toBinary2, cycles 20, operator Disc, edge erode on) Binary Amend (Closefrom Binary2 to Binary3, cycles 8, operator Disc, edge erode on )PauseText (“Toggle <control> and <b> keys to check bump detection andcorrect if necessary.” )  Binary Edit [PAUSE] ( Draw from Binary3 toBinary3, nib Fill, width 2 )  Binary Logical ( copy Binary3, inverted toBinary4 ) IMAGE ACQUISITION 2 - % Open Area Display ( Image0 (on),frames (on,on), planes (off,off,off,off,off,off), lut 0, x 0, y 0, z 1,Reduction off ) PauseText ( “Turn off incident light & ensuretransmitted lighting is correct (WL =  0.97) and acquire image.” ) Image Setup DC Twain [PAUSE] ( Camera 1, AutoExposure Off, Gain 0.00,ExposureTime 34.23 msec, Brightness 0, Lamp 38.83 ) Acquire ( intoImage0 ) DETECT - Open areas only Detect ( whiter than 210, from Image0into Binary10 delineated ) BINARY IMAGE PROCESSING Binary Logical ( C =A AND B : C Binary11, A Binary3, B Binary10 ) Binary Logical ( C = A ANDB : C Binary12, A Binary4, B Binary10 ) MEASURE AREAS - Land,projections, open area within each -- Land Area MFLDIMAGE = 4 Measurefield ( plane MFLDIMAGE, into FLDRESULTS(1), statistics into FLDSTATS(7,1) ) Selected parameters: Area LANDAREA = FLDRESULTS(1) --Projection Area MFLDIMAGE = 3 Measure field ( plane MFLDIMAGE, intoFLDRESULTS(1), statistics into  FLDSTATS(7,1) ) Selected parameters:Area BUMPAREA = FLDRESULTS(1) -- Open Projection area MFLDIMAGE = 11Measure field ( plane MFLDIMAGE, into FLDRESULTS(1), statistics into FLDSTATS(7,1) ) Selected parameters: Area APBUMPAREA = FLDRESULTS(1) --Open land area MFLDIMAGE = 12 Measure field ( plane MFLDIMAGE, intoFLDRESULTS(1), statistics into FLDSTATS(7,1) ) Selected parameters: AreaAPLANDAREA = FLDRESULTS(1) -- Total % open area MFLDIMAGE = 10 Measurefield ( plane MFLDIMAGE, into FLDRESULTS(1), statistics into FLDSTATS(7,1) ) Selected parameters: Area % TOTPERCAPAREA =FLDRESULTS(1) CALCULATE AND OUTPUT AREAS PERCAPLANDAREA =APLANDAREA/LANDAREA*100 PERCAPBUMPAREA = APBUMPAREA/BUMPAREA*100 File (FIELD, channel #1, 0 digits after ‘.’ ) File ( LANDAREA, channel #1, 2digits after ‘.’ ) File ( APLANDAREA, channel #1, 2 digits after ‘.’ )File ( PERCAPLANDAREA, channel #1, 1 digit after ‘.’ ) File ( BUMPAREA,channel #1, 2 digits after ‘.’ ) File ( APBUMPAREA, channel #1, 4 digitsafter ‘.’ ) File ( PERCAPBUMPAREA, channel #1, 5 digits after ‘.’ ) File( TOTPERCAPAREA, channel #1, 2 digits after ‘.’ ) File Line ( channel #1) Stage ( Step, Wait until stopped + 1100 msecs ) Next (FIELD) PauseText( “If no more samples, enter ‘0.’” ) Input ( FINISH ) If ( FINISH=0 )Goto OUTPUT Endif PauseText ( “Place the next replicate specimen on theauto-stage, turn on incident light  and turn-off and/or block sub-stagelighting.” ) Image Setup DC Twain [PAUSE] ( Camera 1, AutoExposure Off,Gain 0.00, ExposureTime 34.23 msec, Brightness 0, Lamp 38.83 ) File Line(channel #1) Next ( SAMPLE ) OUTPUT: Close File ( channel #1 ) END

The QUIPS algorithm is executed using the QWIN Pro software platform.The analyst is initially prompted to enter the material set informationwhich is sent to the EXCEL file.

The analyst is next prompted by a live image set up window on thecomputer monitor screen to place a material onto the auto-stage 308. Thematerial should be laid flat and gentle force applied at its edges toremove any macro-wrinkles that may be present. It should also be alignedso that the machine direction runs horizontally in the image. At thistime, the Circline fluorescent lamp 314 can be on to assist inpositioning the material. Next, the analyst is prompted to adjust theincident Circline fluorescent lamp 314 via the Variable Auto-transformerto a white level reading of approximately 0.9. The sub-stage transmittedlight bank 316 should either be turned off at this time or masked usinga piece of light-blocking, black construction paper placed over the 3inch by 3 inch opening 322.

The analyst is now prompted to ensure that the detection threshold isset to the proper level for detection of the projections using theDetection window which is displayed on the computer monitor screen.Typically, the threshold is set using the white mode at a pointapproximately near the middle of the 8-bit gray-level range (e.g. 127).If necessary, the threshold level can be adjusted up or down so that theresulting detected binary will optimally encompass the projections shownin the acquired image with respect to their boundaries with thesurrounding land region.

After the algorithm automatically performs several binary imageprocessing steps on the detected binary of the projections, the analystwill be given an opportunity to re-check projection detection andcorrect any inaccuracies. The analyst can toggle both the ‘control’ and‘b’ keys simultaneously to re-check projection detection against theunderlying acquired gray-scale image. If necessary, the analyst canselect from a set of binary editing tools (e.g. draw, reject, etc.) tomake any minor adjustments. If care is taken to ensure properillumination and detection in the previously described steps, little orno correction at this point should be necessary.

Next, the analyst is prompted to turn off the incident Circlinefluorescent lamp 314 and either turn on the sub-stage transmitted lightbank or remove the light blocking mask. The sub-stage transmitted lightbank is adjusted by the Variable Auto-transformer to a white levelreading of approximately 0.97. At this point, the image focus can beoptimized for the land areas of the material.

The algorithm, after performing additional operations on the resultingseparate binary images for projections, land areas and open area, willthen automatically perform measurements and output the data into adesignated EXCEL spreadsheet file. The following measurement parameterdata will be located in the EXCEL file after measurements and datatransfer has occurred:

Land Area

Land Open Area

Land % Open Area

Projection Area

Projection Open Area

Projection % Open Area

Total % Open Area

Following the transfer of data, the algorithm will direct the auto-stage308 to move to the next field-of-view and the process of turning on theincident, Circline fluorescent lamp 314 and blocking the transmittedsub-stage lighting bank 316 will begin again. This process will repeatfour times so that there will be five sets of data from five separatefield-of-view images per single material replicate.

Multiple sampling replicates from a single material can be performedduring a single execution of the QUIPS algorithm (Note: The SampleFor—Next line in the algorithm needs to be adjusted to reflect thenumber of material replicate analyses to be performed per material). Thefinal material mean spread value is usually based on an N=5 analysisfrom five, separate, material subsample replicates. A comparison betweendifferent materials can be performed using a Student's T analysis at the90% confidence level.

Method to Determine Height of Projections Test Method:

The height of the projections can be determined by using the imageanalysis measurement method described herein. The image analysis methoddetermines a dimensional numeric height value for projections usingspecific image analysis measurements of both land areas and projectionswith underlying land regions in a sample and then calculating theprojection height alone by difference between the two. The projectionheight method is performed using conventional optical image analysistechniques to detect cross-sectional regions of both land areas andprojection structures and then measure a mean linear height value foreach when viewed using a camera with incident lighting. The resultingmeasurement data are used to compare the projection heightcharacteristics of different types of body-side intake layers.

Prior to performing image analysis measurements, the sample of interestmust be prepared in such a way to allow visualization of arepresentative cross-section that passes thru the center of aprojection. Cross-sectioning can be performed by anchoring arepresentative piece of the sample on at least one of its cross-machinerunning straight edges on a flat, smooth surface with a strip of tapesuch as ¾ inch SCOTCH® Magic™ tape produced by 3M. Cross-sectioning isthen performed by using a new, previously unused single edge carbonsteel blue blade (PAL) and carefully cutting in a direction away fromand orthogonal to the anchored edge and thru the centers of at least oneprojection and preferably more if projections are arranged in rowsrunning in the machine direction. Any remaining rows of projectionslocated behind the cross-sectioned face of projections should be cutaway and removed prior to mounting so that only cross-sectionedprojections of interest are present. Such blades for cross-sectioningcan be acquired from Electron Microscopy Sciences of Hatfield, Pa. (Cat.#71974). Cross-sectioning is performed in the machine-direction of thesample, and a fresh, previously unused blade should be used for each newcross-sectional cut. The cross-sectioned face can now be mounted so thatthe projections are directed upward away from the base mount using anadherent such as two-side tape so that it can be viewed using a videocamera possessing an optical lens. The mount itself and any backgroundbehind the sample that will be viewed by the camera must be darkenedusing non-reflective black tape and black construction paper 346 (shownin FIG. 23 ), respectively. For a typical sample, enough cross-sectionsshould be cut and mounted separately from which a total of sixprojection height values can be determined.

An exemplary setup for acquiring the images is representativelyillustrated in FIG. 23 . Specifically, a CCD video camera 330 (e.g., aLeica DFC 310 FX video camera operated in gray scale mode is availablefrom Leica Microsystems of Heerbrugg, Switzerland) is mounted on astandard support 332 such as a Polaroid MP-4 Land Camera standardsupport available from Polaroid Resource Center in Cambridge, Miss. orequivalent. The standard support 332 is attached to a macro-viewer 334such as a KREONITE macro-viewer available from Dunning Photo Equipment,Inc., having an office in Bixby, Okla. An auto stage 336 is placed onthe upper surface of the macro-viewer 334. The auto stage 336 is used tomove the position of a given sample for viewing by the camera 330. Asuitable auto stage 336 is a Model H112, available from Prior ScientificInc., having an office in Rockland, Mass.

The darkened sample mount 338 exposing the cross-sectioned sample facepossessing land areas and projections is placed on the auto stage 336under the optical axis of a 50 mm Nikon lens 340 with an f-stop settingof 2.8. The Nikon lens 340 is attached to the Leica DFC 310 FX camera330 using a 30 mm extension tube 342 and a c-mount adaptor. The samplemount 338 is oriented so the sample cross-section faces flush toward thecamera 330 and runs in the horizontal direction of the resulting imagewith the projections directed upward away from the base mount. Thecross-sectional face is illuminated with incident, incandescent lighting344 provided by two, 150 watt, GE Reflector Flood lamps. The two floodlamps are positioned so that they provide more illumination to thecross-sectional face than to the sample mount 338 beneath it in theimage. When viewed from overhead directly above the camera 330 andunderlying sample cross-section mount 338, the flood lamps 344 will bepositioned at approximately 30 degrees and 150 degrees with respect tothe horizontal plane running thru the camera 330. From this view thecamera support will be at the 90 degree position. The illumination levelof the lamps is controlled with a Variable Auto-transformer, type3PN1010, available from Staco Energy Products Co. having an office inDayton, Ohio.

The image analysis software platform used to perform measurements is aQWIN Pro (Version 3.5.1) available from Leica Microsystems, having anoffice in Heerbrugg, Switzerland. The system and images are alsocalibrated using the QWIN software and a standard ruler with metricmarkings at least as small as one millimeter. The calibration isperformed in the horizontal dimension of the video camera image. Unitsof millimeters per pixel are used for the calibration.

Thus, the method for determining projection heights of a given sampleincludes the step of performing several, dimensional measurements.Specifically, an image analysis algorithm is used to acquire and processimages as well as perform measurements using Quantimet User InteractiveProgramming System (QUIPS) language. The image analysis algorithm isreproduced below.

NAME = Height − Projection vs Land Regions − 1 PURPOSE = Measures heightof projection and land regions DEFINE VARIABLES & OPEN FILES  -- Thefollowing line is set to designate where measurement data will bestored. Open File (C:\Data\39291\Height\data.xls, channel #1) FIELDS = 6SAMPLE ID AND SET UP Enter Results Header File Results Header ( channel#1 ) File Line ( channel #1 ) Measure frame ( x 31, y 61, Width 1330,Height 978 ) Image frame ( x 0, y 0, Width 1392, Height 1040 )  --Calvalue = 0.0083 mm/pixel CALVALUE = 0.0083 Calibrate ( CALVALUECALUNITS$ per pixel ) For ( REPLICATE = 1 to FIELDS, step 1 ) ClearFeature Histogram #1 Clear Feature Histogram #2 Clear Accepts IMAGEACQUISITION AND DETECTION PauseText ( “Position sample, focus image andset white level to 0.95.” ) Image Setup DC Twain [PAUSE] ( Camera 1,AutoExposure Off, Gain 0.00, ExposureTime 200.00 msec, Brightness 0,Lamp 49.99 ) Acquire ( into Image0 ) ACQOUTPUT = 0  -- The followingline can be optionally set-up for saving image files to a specific location. ACQFILE$ = “C:\Images\39291 - for Height\Text. 2H_”+STR$(REPLICATE)+“s.jpg” Write image ( from ACQOUTPUT into fileACQFILE$ ) Detect ( whiter than 104, from Image0 into Binary0 delineated) IMAGE PROCESSING Binary Amend (Close from Binary0 to Binary1, cycles4, operator Disc, edge erode on) Binary Amend (Open from Binary1 toBinary2, cycles 4, operator Disc, edge erode on) Binary Identify(FillHoles from Binary2 to Binary3) Binary Amend (Close from Binary3 toBinary4, cycles 15, operator Disc, edge erode on) Binary Amend (Openfrom Binary4 to Binary5, cycles 20, operator Disc, edge erode on)PauseText ( “Fill in projection & land regions that should be included,and reject over detected regions.” ) Binary Edit [PAUSE] ( Draw fromBinary5 to Binary6, nib Fill, width 2 ) PauseText ( “Select ‘Land’region for measurement.” ) Binary Edit [PAUSE] ( Accept from Binary6 toBinary7, nib Fill, width 2 ) PauseText ( “Select ‘Projection’ region formeasurement.” ) Binary Edit [PAUSE] ( Accept from Binary6 to Binary8,nib Fill, width 2 ) -- Combine land and projection regions withmeasurement grid. Graphics ( Grid, 30 x 0 Lines, Grid Size 1334 x 964,Origin 21 x 21, Thickness 2, Orientation 0.000000, to Binary15 Cleared )Binary Logical ( C = A AND B : C Binary10, A Binary7, B Binary15 )Binary Logical ( C = A AND B : C Binary11, A Binary8, B Binary15 )MEASURE HEIGHTS -- Land region only Measure feature ( plane Binary10, 8ferets, minimum area: 8, grey image: Image0 ) Selected parameters: XFCP, Y FCP, Feret90 Feature Histogram #1 ( Y Param Number, X ParamFeret90, from 0.0100 to 5.,  logarithmic, 20 bins ) Display FeatureHistogram Results ( #1, horizontal, differential, bins + graph (Y axislinear), statistics ) Data Window ( 1278, 412, 323, 371 ) -- Projectionregions only (includes any underlying land material) Measure feature (plane Binary11, 8 ferets, minimum area: 8, grey image: Image0 ) Selectedparameters: X FCP, Y FCP, Feret90 Feature Histogram #2 ( Y Param Number,X Param Feret90, from 0.0100 to 10.,  logarithmic, 20 bins ) DisplayFeature Histogram Results ( #2, horizontal, differential, bins + graph(Y axis linear), statistics ) Data Window ( 1305, 801, 297, 371 ) OUTPUTDATA File ( “Land Height (mm)”, channel #1 ) File Line ( channel #1 )File Feature Histogram Results ( #1, differential, statistics, bindetails, channel #1 ) File Line ( channel #1 ) File Line ( channel #1 )File ( “Projection + Land Height (mm)”, channel #1 ) File Line ( channel#1 ) File Feature Histogram Results ( #2, differential, statistics, bindetails, channel #1 ) File Line ( channel #1 ) File Line ( channel #1 )File Line ( channel #1 )  Next ( REPLICATE )  Close File (channel #1)END

The QUIPS algorithm is executed using the QWIN Pro software platform.The analyst is initially prompted to enter sample identificationinformation which is sent to a designated EXCEL file to which themeasurement data will also be subsequently sent.

The analyst is then prompted to position the mounted samplecross-section on the auto-stage 336 possessing the darkened backgroundso the cross-sectional face is flush to the camera 330 with projectionsdirected upward and the length running horizontally in the live imagedisplayed on the video monitor screen. The analyst next adjusts thevideo camera 330 and lens' 340 vertical position to optimize the focusof the cross-sectional face. The illumination level is also adjusted bythe analyst via the Variable Auto-transformer to a white level readingof approximately 0.95.

Once the analyst completes the above steps and executes the continuecommand, an image will be acquired, detected and processed automaticallyby the QUIPS algorithm. The analyst will then be prompted to fill-in thedetected binary image, using the computer mouse, of any projectionand/or land areas shown in the cross-sectional image that should havebeen included by the previous detection and image processing steps aswell as rejecting any over detected regions that go beyond theboundaries of the cross-sectional structure shown in the underlyinggray-scale image. To aid in this editing process, the analyst can togglethe ‘control’ and ‘B’ keys on the keyboard simultaneously to turn theoverlying binary image on and off to assess how closely the binarymatches with the boundaries of the sample shown in the cross-section. Ifthe initial cross-sectioning sample preparation was performed well,little if any manual editing should be required.

The analyst is now prompted to “Select ‘Land’ region for measurement”using the computer mouse. This selection is performed by carefullydrawing a vertical line down through one side of a single land arealocated between or adjacent to projections and then, with the left mousebutton still depressed, moving the cursor beneath the land area to itsopposite side and then drawing another vertical line upward. Once thishas occurred, the left mouse button can be released and the land area tobe measured should be filled in with a green coloring. If the verticaledges of the resulting selected region are skewed in any way, theanalyst can reset to the original detected binary by clicking on the‘Undo’ button located within the Binary Edit window and begin theselection process again until straight vertical edges on both sides ofthe selected land region are obtained.

Similarly, the analyst will next be prompted to “Select ‘Projection’region for measurement.” The top portion of a projection region adjacentto the previously selected land area is now selected in the same mannerthat was previously described for a land area selection.

The algorithm will then automatically perform measurements on bothselected regions and output the data, in histogram format, into thedesignated EXCEL spreadsheet file. In the EXCEL file, the histograms forland and projection regions will be labeled “Land Height (mm)” and“Projection+Land Height (mm),” respectively. A separate set ofhistograms will be generated for each selection of land and projectionregion pairs.

The analyst will then again be prompted to position the sample and beginthe process of selecting different land and projection regions. At thispoint, the analyst can either use the auto-stage joystick to move thesame cross-section to a new sub-sampling position or an entirelydifferent mounted cross-section obtained from the same sample can bepositioned on the auto-stage 306 for measurement. The process forpositioning the sample and selecting land and projection regions formeasurement will occur six times for each execution of the QUIPSalgorithm.

A single projection height value is then determined by calculating thenumerical difference between the mean values of the separate land andprojection region histograms for each single pair of measurements. TheQUIPS algorithm will provide six replicate measurement sets of both landand projection regions for a single sample so that six projection heightvalues will be generated per sample. The final sample mean spread valueis usually based on an N=6 analysis from six, separate subsamplemeasurements. A comparison between different samples can be performedusing a Student's T analysis at the 90% confidence level.

In the interests of brevity and conciseness, any ranges of values setforth in this disclosure contemplate all values within the range and areto be construed as support for claims reciting any sub-ranges havingendpoints which are whole number values within the specified range inquestion. By way of hypothetical example, a disclosure of a range offrom 1 to 5 shall be considered to support claims to any of thefollowing ranges 1 to 5; 1 to 4; 1 to 3; 1 to 2; 2 to 5; 2 to 4; 2 to 3;3 to 5; 3 to 4; and 4 to 5.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

All documents cited in the Detailed Description are, in relevant part,incorporated herein by reference; the citation of any documents is notto be construed as an admission that it is prior art with respect to thepresent invention. To the extent that any meaning or definition of aterm in this written document conflicts with any meaning or definitionof the term in a document incorporated by reference, the meaning ordefinition assigned to the term in this written document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

When introducing elements of the present disclosure or the preferredembodiment(s) thereof, the articles “a”, “an”, “the” and “said” areintended to mean that there are one or more of the elements. The terms“comprising”, “including” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements. Many modifications and variations of the present disclosurecan be made without departing from the spirit and scope thereof.Therefore, the exemplary embodiments described above should not be usedto limit the scope of the invention.

What is claimed is:
 1. An absorbent article comprising: a) alongitudinal direction and a transverse direction; b) a longitudinalcenterline and a transverse centerline; c) an anterior region, aposterior region, and a central region positioned between the anteriorregion and the posterior region; d) an anterior region transversedirection end edge, a posterior region transverse direction end edge,and a pair of longitudinal direction side edges extending between andconnecting the anterior region transverse direction end edge and theposterior region transverse direction end edge; e) a topsheet layerdefining a body facing surface of the absorbent article, a liquidimpermeable layer defining a garment facing surface of the absorbentarticle, and an absorbent core positioned between the topsheet layer andthe liquid impermeable layer; and f) an exudate management layer formedof a base sheet of material and in fluid communication with the topsheetlayer; the exudate management layer comprising a first opening and asecond opening, wherein at least one of the first opening or the secondopening is further connected to a barrier component via a barriercomponent fold, the barrier component extending from the barriercomponent fold in the longitudinal direction towards the posteriorregion of the absorbent article, wherein the barrier component is formedfrom the same base sheet of material forming the exudate managementlayer and is formed by separating the material forming the barriercomponent from the material forming the exudate management layer andfolding at the barrier component fold.
 2. The absorbent article of claim1 wherein the exudate management layer comprises a first component atleast partially defining the first opening and the second opening. 3.The absorbent article of claim 1 wherein the exudate management layercomprises a first component at least partially defining the firstopening and a second component at least partially defining the secondopening wherein the second component is connected to the first componentvia a primary fold.
 4. The absorbent article of claim 1 wherein theexudate management layer is positioned on the body facing surface of thetopsheet layer.
 5. The absorbent article of claim 1 wherein the exudatemanagement layer is positioned between the topsheet layer and theabsorbent core.
 6. The absorbent article of claim 1 further comprisingan acquisition layer.
 7. The absorbent article of claim 1 wherein thebarrier component comprises a secondary fold.
 8. The absorbent articleof claim 1 wherein the second component at least partially overlaps thefirst component.
 9. The absorbent article of claim 1 wherein secondcomponent at least partially underlaps the first component.
 10. Theabsorbent article of claim 1 wherein the absorbent article furthercomprises an opposing pair of containment flaps extending in thelongitudinal direction of the absorbent article.
 11. The absorbentarticle of claim 1 wherein the topsheet layer is a fluid entangledlaminate web comprising a support layer comprising a plurality of fibersand opposed first and second surfaces; a projection layer comprising aplurality of fibers and opposed inner and outer surfaces, the secondsurface of the support layer in contact with the inner surface of theprojection layer, fibers of at least one of the support layer and theprojection layer being fluid-entangled fibers of the other of thesupport layer and the projection layer; a plurality of hollowprojections formed form a first plurality of the plurality of fibers inthe projection layer, the plurality of hollow projections extending fromthe outer surface of the projection layer in a direction away from thesupport layer; and a land area, wherein the plurality of hollowprojections are surrounded by the land area.
 12. The absorbent articleof claim 1 wherein the absorbent core comprises a body facing surfaceand projections extending away from the body facing surface of theabsorbent core.
 13. The absorbent article of claim 1 wherein the barriercomponent comprises at least one opening.